It’s been a struggle putting together a design for a workbench. Not because I don’t know what I want to make, but because I need to figure out the best way to make it by hand from construction lumber. I have about 60 linear feet of Douglas Fir 2×10’s that will become the frame, and I plan to laminate over a dozen Douglas Fir 2×4’s for the top, but creating a step-by-step plan has been elusive.
And for me, that means taking a step back from the theoretical and diving into some practical research. And what could be a better practice run than those Japanese-style Saw Horses I’ve always wanted? And what better place to start than the feet, which are a perfect scale analogue for the laminated workbench legs?
Each foot is approximately 24″ long and consists of two boards. I don’t have any 2×4’s, but I do have some 2×8’s and a panel saw, so here we go!
Step one: rip a 48″ 2×8 into two lengths of 2×4, then crosscut to 24″ each and reassemble in sequence.
Step two: carefully mark where the boards meet, and stack each right board on top of the corresponding left board without changing orientation.
Step three: surface plane the two faces where the boards will meet, then square up one edge to each reference face.Step four: thickness plane each board to S4S and prepare for glue up.
[Picture not found…yet.]
Before I actually glue up the feet, though, I should create the mortises for the legs by cutting dadoes in the reference faces. The bottoms are already square to those reference faces, so there is no reason I can’t cut those joints in advance of thicknessing.
The legs, btw, will be made from approximately 30″ of Douglas Fir 2×6. But that, along with the top and bottom cross rails, is for another day.