Increasing the Shop a Bit

I had to put a pause on the workbench and vise for a little while to clean up and rearrange the shop (and the shed, and the laundry room).  This gave me some more elbow room in the shop. You have to do some reorganizing and purging once in a while... :)

20200924_151634
20200924_151634


Shaker Workbench, The Top, Part 1

Well now, making the top for the Shaker workbench is turning out to be a whole 'nother project on its own!

 

Cutting white ash boards, 18 in all, to rough size and milling to final thickness/width...

20200730_155254
20200730_155254
20200730_155254

Making some heavy duty clamping cauls out of SuperStrut, and some clamping stands out of plywood...

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20200806_135148
20200806_135148

Laminating 3 "sub-slabs" of 6 boards each: glue, cauls, clamps...

20200817_113624
20200817_113624

Running the 3 sub-slabs through the jointer and planer to get them to almost final thickness...

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20200810_143705
20200810_143705

Doing another glue-caul-clamp process, this time to join the 3 sub-slabs into one monster top piece. The cauls worked wonderfully, necessitating only a little glue scraping at the seams, and the top was flat and smooth. MANY thanks go to my lovely and gracious Glue-Up Helper Squad! :)

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20200820_105940

To be continued, after we recuperate and eat some more Wheaties... :)  :)

 


Pegs and Paint

Some last things to do before assembly of the base...

 

Cut the 3/8" drawbore pegs from cherry dowel stock; use a pencil sharpener to chamfer the ends (to make it easier for the pegs to wiggle through the offset holes)...

20200713_135743
20200713_135743

Final prep on the panels - sanding the outside faces, using a block plane to make some light chamfers on the edges:

20200713_105452
20200713_105452
20200713_105452

Applying 3 coats of milk paint on the outside faces of the panels. Apparently this is something that Shaker craftsmen would do on the secondary woods of their benches:

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20200714_202901
20200714_202901

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20200714_154928
20200714_154928


Shaker Workbench - Base Joinery, Panels, Dry Assembly

Continuing on the base for the Shaker workbench...

 

Stopped-  and through-groove joinery on the legs, stretchers, mullions:

Stoppedgroovesontablesaw
Stoppedgroovesontablesaw

Making the 15 soft maple panels (with tongue and groove joinery) that will wrap around the sides and back of the base:

20200707_112141
20200707_112141

Using the router table to cut decorative beads on the edges of the panels:

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20200710_112946

Doing some dry test assembly and making some fine adjustments to make sure the pieces will easily fit together when we do the actual glue-up:

20200710_115323
20200710_115323

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20200710_141113
20200710_141113

Next up:

Surface prep, milk-painting the panels, and the big base assembly!

 


Base Frame Tenons, Dry Test Assemble

With the leg mortises done, it was time to move onto making the tenons on the stretcher beams, end stretchers, and back mullions.

 

Test cuts, test fits, and cutting shoulders on the table saw...

20200622_153610
20200622_153610
20200622_153610

Cutting the tenon cheeks for the large stretchers on the bandsaw...

20200622_153610

Finessing the shape and size of the tenons using a chisel, block plane, and sandpaper...

20200625_115526

 

Doing a dry test assembly...
20200625_115526
20200625_115526
20200625_115526

That's looking like a pretty beefy base frame!

 


Leg Mortises

The Shaker workbench will have a pretty beefy frame, and the main joinery between the legs and rails will be mortise and tenon. Here we are getting the leg mortises cut...

First - mark the layout lines, and hog out the mortises using the Festool XL:

Capture
Capture

Then finesse the mortise walls with chisels to clean up the ridges:

20200606_133700
20200606_133700

Drill out the peg holes that will be used for the drawbores on the tenons that fit into the mortises...

20200606_141310


Electric Fence

So, this spring I have a handful of house/yard projects to get worked in between stints on the new workbench build.

Last summer late, some of the local deer re-discovered our gardens, and in one night almost completely wiped out everything that had been grown, wasting a whole season's worth of labor by Hannah. So this year, we decided to install an electric fence around both gardens to deter them from coming back.

 

Making up the insulator mounts and installing them on the fences, installing the polywire...

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20200418_122259
20200418_122259
20200418_122259
20200418_122259

Installing the ground rod and solar fence charger...

20200422_150054
20200422_150054
20200422_150054

Running underground cable from the solar charger to the fence wires...

Solarchargertofence1
Solarchargertofence1
Solarchargertofence1

Ready for action...

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