Shop Equipment

New Year’s Day, 2022

Another year has passed. As is my heathen wont, I went to bed early last night, stone sober and well hydrated, and hit the shop early this morning. I like to begin each year on my own terms. And then ride out the downhill trajectory from there.

In advance of my regular January vacation, I’ve been making a “gentleman’s tool chest” for a core set of hand tools. Now I’m no gentleman (or so I’ve been told), but as I understand it, the “gentleman” refers simultaneously to (x) a non-professional woodworker and (y) the smaller set of tools a non-professional joiner or cabinetmaker would have in their chest. So maybe I am a gentleman.

This particular tool chest is a modest 25″ long, 11″ deep and 11″ high and will have 2 sliding tills. The planes and sharpening gear are french fit into the tool well and there won’t be too much lose gear rattling around. It’s also intended to be a general around-the-house toolbox holding my nicest spare tools so it will move around a fair bit.

Still one more sliding till to make.

In any tool storage build, like in life, there are compromises. For example, there is not any room for joinery saws in this chest, but I have modified a 10 tpi rip saw (it crosscuts too) and a 6 tpi rip saw to have shorter plates. I say modified; I cutoff about 5 inches from the toe of each saw with an angle grinder and filed off the burrs. The shorter plates are stiff enough for precise sawing as needed (and everything gets cleaned up with chisel or router plane anyway).

It’s also rabbeted and nailed, not dovetailed. Cauls help keep everything flat when nailing together.

The full kit this holds is as follows:

  • Planes: No. 5 jack plane, No. 3 smoothing plane, Low-angle block plane, small router plane
  • Saws: 10 tpi rip cut panel saw (18″ plate): 6 tpi rip cut panel saw (18″ plate)
  • Chisels: 1/4, 1/2, 3/4, 1 inch bench chisels, carver’s mallet
  • Marking and measuring: 12″ combination square, 8″ machinist square, wheel marking gauge, 12 foot tape measure, folding marking knife, mechanical pencils
  • Boring: Two jaw, short sweep brace, plus hex adapter, large diameter adjustable auger bit, drill bit set, hand countersink
  • Sharpening: 120, 220, 1200 grit diamond plates, side clamp honing guide and setup block, plus glass cleaner and jojoba oil
  • Miscellaneous: Warrington-pattern hammer, slotted and phillips screwdrivers, cork sanding block, foam ear plugs (lots of these)

I’m sure there is something I’m forgetting (I can supplement this later), but I find the above set of tools is everything one needs for general woodworking projects that aren’t intended to be the finest furniture. I can take rough lumber to dimension with these tools and do crisp joinery by hand without too much fuss. I will likely make or purchase a medium router plane to fit this chest, as well as a set of wooden winding sticks and a wooden straightedge.

As I write this, the second till is glued and nailed and drying in the shop. So that means only one thing: it’s lid time.

And that’s the point at which every tool chest build starts to get tedious.

Happy New Year, everyone!

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Fixgasm (Part II)

Speaking of fixgasms, I finally got around to installing the Veritas Inset Vise in my Moravian Workbench. It’s not quite a revelation, but I’m glad I did it and it officially completes the workbench.

Works like a charm.

For those who aren’t familiar, it’s a compact, easy to install, and well made tail vise option for benchtops of pretty much any thickness of 1.5″ (38mm or so). It’s really a carriage vise or wagon vise that’s easily retrofittable into any benchtop of sufficient thickness. HNT Gordon makes a similar option, but I’ve never used one of those.

I’ve had this inset vise for a while (which was a Christmas present from my parents few years ago). It used to live in another workbench before I gave that away. Veritas/Lee Valley is not a sponsor btw (no one is, lol). They just make great tools, especially bench appliances.

Maximum capacity of 68.5 inches (1740mm or so). More if I use a clamp on the far end to gain another inch or so.

To use a tail vise of any sort, you’ll need a row of bench dog holes in line with the movable jaw on the tail vise (see above). Pinch a board on its face or edge between the dog in the bench and the dog in the tail vise and it stays put. For planing in any direction (especially traversing across the grain or at a diagonal). For mortising or other detail work on the face of the board. If the line of dog holes is close enough to the front edge of the bench, you can use it like a sticking board for use with fenced joinery planes (like a rabbeting or fillister plane).

I like a good tail vise, although series of pegs or a holdfast and doe’s foot are just as good in my book. I wasn’t sure I’d ever install the inset vise into this particular bench, but when laying out the overall size of the undercarriage. I’d gotten by just fine with those other options, but it was time to finish this off.

So now that it’s finished, I would imagine I’ll immediate move on to another workbench.

LOL. Just kidding. Not really. Maybe?

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Woodworking Workbench for Sale!

I’m out of room in my workshop. Between my Moravian and my Nicholson, my workshop proper is full. And my overflow room (where my thickness planer and hollow chisel mortiser are) is full too (mostly of lumber). So that leaves me with a superfluous workbench which I’d like to find a good home.

Yes, that is the repurposed top from the last time I tried to sell this giant hunk of ash.

The workbench is a modified Roubo style. It’s stretcherless; the way I like it, although you could easily nail on a couple of short stretchers (a la the Vasa workbench) if you wanted to add storage to the bottom.

The front legs have the traditional Roubo joint (tenon with sliding dovetail), but the back legs are angled out around 14 degrees and glued and bolted on kind of like the legs on a Schwarz-style saw bench.

Overall dimensions are as follows (everything is solid ash, except for the vise chop, which is white oak):

Top: 90.5 inches long x 14.875″ deep by 3.75″ thick

Base: 58 inches long x 24″ deep (legs are 6″ x 3″)

Accessories: DIY Leg vise (1.5″ screw, pin board style) and 2x DIY bench dogs (1″ holdfast and dog holes)

With leg vise

$500 firm (just recouping the cost of the slab top material; I enjoyed making it and want someone to enjoy using it). And you’ve got to pick it up in lower Fairfield County, Connecticut. No shipments; no exceptions. I will help you load it in the truck, though.

Email: theapartmentwoodworker@gmail.com if you’re interested.

More pictures:

Leg detail (three dog/holdfast holes at 1″)
Back leg joint detail. Lots of face grain glue surface here, plus the bolt.
Slab detail. Perfect for adding a tool stray or a wing to extend the benchtop.

The Importance of Instructions

We are fortunate to live in the world we do now, even with all its faults. The entirety of catalogued human knowledge is available at our fingertips and we mostly take it for granted. As I write this, I have the cabinet making and marquetry chapter of Diderot’s Encyclopedia open in one tab (specifically, plate 21-2-9, but more on that another day) and a 2016 Fine Woodworking workbench article with a fantastic tutorial on how to make a tail vise using commercially-available hardware, open in background browser tabs. That second one is pretty important, because I’m making a tail vise to retrofit on a work bench and the hardware I bought from Lee Valley doesn’t come with instructions. Like at all (which is weird, because LV usually goes overboard with the literature included in their products).

So I had to turn to the internet. I first checked the Woodcraft website (they sell a similar product), but the included instructions are rather cryptic). Also, the product picture on the website has the screw backwards, which I found odd. Then I scoured YouTube for an instructional on using this hardware and came up empty. So I searched “tail vise installation guide” and bam: the FW article popped up near the top.

It’s a 10-page article and the author spends 4(!) pages detailing exactly how to build, fit and tune a tail vise. The entire article is fantastic, but I have absolutely no intention of making the workbench in the FW article. However, I give the author much credit for taking the time to explain in great detail the difficult and unintuitive part of the build (the tail vise). There is more useful information in those 4 pages than in the entirety of most other woodworking project articles. And how many woodworking articles yadda yadda the difficult stuff like some sawdust-covered underpants gnome.

This is as far as I can take it until I attach it to the actual bench.

What you see above is the “core” of the tail vise. Essentially, it’s a laminated block of wood with a recess in the middle the vise nut (which is on the inside of the mounting plate) and a rabbet that accepts the top guide plate. There is also a clearance hole drilled on the right side for the vise screw to pass through. The the vise hub screws onto the right hand side, and I may sink some dowels perpendicular to the core to give the vise hub mounting screws more purchase. I learned that trick from a Popular Woodworking video series on a Torsion Box Workbench.

The tail vise assembly is completed by adding a “dog strip” with bench dog holes (the point of a tail vise is to pinch a board between dogs, after all) and a top plate that looks pretty and covers the top guide plate (and brings the top of the tail vise flush with the benchtop to which the vise is mounted). I made the core out of hard maple, but the dog strip and top plate will be whatever wood the benchtop to which it’s mounted is made. In this case, it will be ash. But this tail vise core is evergreen, especially if I attach the dog strip and top plate with hide glue.

I would note that for the LV version, you’ll need to add some washers to the bolts that attach the guide plates. This ensures the bolts (which thread into the top guide plate) sit just below the surface.

Why do I mention all this, you ask? Well, there is a trope about men not reading the instructions. Which I’ve never understood, mostly because of my father. He was a Navy pilot during the Vietnam War and a commercial airline pilot until he retired (although a good chunk of his career was as a flight instructor). If there is a man who appreciates good instructions, it’s my father (and he passed that appreciation on to me). In fact, it’s my mother who doesn’t read instructions and it frustrates us both to no end.

So, for your own sake, read the god damned instructions. Especially if you can actually find them.

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Fixgasm (noun)

Fixgasm (noun): a small, heavily-procrastinated DIY project that, when completed, has a significant effect on efficiency or enjoyment of the object or space.

Example:

Finally added the spacer between the split top.

Having a split top workbench with a gap between the slabs is quite convenient for weird clamping jobs. But the gap is not so convenient for keeping tools off the floor. With a bit of time today, though, I managed to fit the center spacer to fill the gap. I’d been meaning to do this for a while and, other than the ripping of 12/4 ash to make the strip, it was pretty easy and should have been done a while ago.

Classic fixgasm.

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Workshop Update (Q2 2021)

Those of you who follow me on the twitterbook know that I recently rearranged my workshop. I think it’s really great, especially now that my main workbench is under a window (south facing as it may be). And you may notice something about the main workbench itself: it’s a forest green Moravian knock down! Albeit a split-top variety.

I also upgraded the overhead lighting, as if natural light wasn’t good enough!

With the new workbench rotating in, my eight foot Nicholson shifted against the wall where my tool chest used to live and my clamp racks still do. And my sharpening station is not on the right end of that bench, with the old sharpening station (a 4-foot Paul Seller’s workbench clone) having moved to another home. I still use the leg vise from time to time, because I love the foot-operated cog and screw parallel guide just so much. The Moravian workbench has a pinboard, which is fine but much less convenient (more on that in the future).

I still like this workbench, it’s just very large and was taking up too much room in the middle of the space.

All in all, the new arrangement improves the flow of the workshop and the room actually feels bigger despite having another 4 square feet of overall workbench footprint (it’s a 13.5′ x 12.5′ bedroom, btw).

I need to work with the Moravian workbench for a few more months to get a better sense of how it fits my workflow.

So stay tuned!

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Cultural Appreciation (Pt. II)

Many moons ago, although surprisingly still in pandemic times, I made a small sitting bench out of scrap pine (Eastern White Pine for the top and Red Pine for the legs) that used angled, rectilinear tenons and a cross-rail on each end. After watching Grandpa Amu make a new workbench several times, this was an experiment and study in how these sorts of angled tenons work. The legs splay out at 10 degree (ish) angles, but have no rake. At the time, that seemed to me a good first step and was actually doable without any guides or other jigs. Just a chisel and a bevel gauge and some caution.

This thing, that actually lives at my office now.

Shortly after that, I took a six foot piece of 8″ wide clear vertical grain douglas fir that was languishing in the lumber pile and turned it into slab top and four square legs for the next part of the experiment. Which then sat, leaned up against the wall, for almost a year. But the spirit moved me this weekend and I got back to it. For this piece, the legs would have both splay and rake (both at around 10 degrees). And it’s worked out nicely (and not just because CVG douglas fir is very handtool friendly).

That’s my new Moravian workbench behind, including the finished leg vise, in my rearranged shop.

Shortly after the original experiment, I made a couple of test mortises (also in Eastern White Pine) using the same technique as the first bench (freehand with only a bevel gauge to assist). They didn’t come out great, with the bottom of the mortise (on the underside) being wider than the top. This led to inconsistent leg angles that couldn’t be wholly attributed to the softness of the EWP top.

So what I did instead was cut a few angle guides from squared up 2×4 (more on that in a future post). That way, I could freehand close to the lines and then, in a final paring cut using the guides, get the angles dead on. At least within appropriate tolerances for a piece of furniture. I’m no machinist, after all.

On the right, you can see a couple of low spots where freehand chopping took me a smidge below the final angle.

So was it strictly necessary to go through all this fuss to make the angles perfect? Probably not. I’ve already drilled the peg holes into the top and this will live as a saw bench in my shop (replacing a pair that are about 6 years old and wearing out quickly). It didn’t need to be perfect.

But if I were to use a joint like this in a proper piece of furniture, I think the angle paring guides are the way to go. Could I eventually get good enough freehanding to not need the guides as a crutch. Sure. But that’s a lot of work and, in my view, if a simple jig works, it’s worth using.

And, for now, I’ll gladly use whatever help I can get.

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Secret Plans

Tell me if this sounds familiar: a friend or relation knows you can make things (in my case, out of wood) and are otherwise handy at need. Instead of paying a professional, whose livelihood depends on finding jobs like this, they ask you, an amateur to make or fix or modify something. Being a good friend/relation/human being, you dutifully pack up your traveling tool box with what you think you’ll need and, before you go, ask the person to confirm they have a decent workbench to work on, or at least a sturdy table for you to clamp a portable workbench to. They of course respond “yes”.

Then you show up. Their “workbench” is a bit of screwed together 2×4 and plywood that sways like a willow in a hurricane from the lightest wracking force. Even worse, it’s a plastic, folding card table. Or their partner won’t let you clamp your portable workstation to their IKEA dining room table. You can’t work like this, so eventually you make portable workbench that doesn’t rely on clamping to another stable platform (like a staked, roman-style workbench). But those are a pain (literally and figuratively) to move around.

Do this enough times, and your conclusion will be “why don’t I just make all my friends and relatives workbenches, so I always have one handy when they ask me to help with something?”. And your conclusion is correct. I, myself, have been secretly filling my friends’ and relatives’ homes with proper workbenches for years.

I ran out of whole 2×4’s so I laminated in some “clamping gaps” with scraps.

The bench above is a pretty faithful representation of Will Myer’s “Moravian Workbench”, other than it’s entirety constructed from Douglas Fir 2×4’s (except the wedges, which are red oak, and the tray, which is poplar). And I omit the leg vise.

Pre-pandemic, the twenty 2×4’s needed to make this entire workbench would cost about US$80 in total. Add in an oak hobby board for the wedges and a bottle of PVA glue and you’re barely pushing $100 for the raw materials. Unfortunately, with the lumber prices being what they right now, the materials would currently cost almost twice as much.

But that’s okay. A good workbench at a friend or relative’s home is worth its weight in figurative gold.

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The Last Train Home

I’ve resisted it for a while, but finally gave in to this Roubo Workbench craze (if you can call something at least 15 years old a craze). Not because I need it (I have to many workbenches already); but because I need to prove to myself that I can do it.

I was never able to sell my old workbench, so cut the back wing off the slab and set that side after plugging the holdfast holes with epoxy and covering them with poorly matching dutchmen. That repurposed wing is still about 3″ thick and 7 inches wide and will become something, eventually. Probably a mantle, if I’m being honest.

Slab Rehab!

The main slab was still about 3.75″ thick, even after several flattenings. It’s 90″ long and about 15″ wide, consisting of two boards edge glued together. It started as a single, 180″ long piece of 16/4 ash, as a reminder. And after 5 years or so seems to be pretty dry and stable. And the holdfast holes are still pretty plumb even after all that flattening. This is no 6″ thick, 24″ wide slab of green red oak. 15″ is far too narrow for all four legs to be straight up and down (the bench would be too tippy).

So that means another weird Stent Panel (i.e., stretcher-less) style workbench!

It’s still a nice slab.

I’ve made a quasi-Stent Panel workbench before, with angled back legs. Unlike the last time, though, I won’t mortise the angled back legs into the underside of the slab. Instead, just like a saw bench, I’ll dado the back legs into the side of the slab and cut an angled lap joint on the leg itself. Glue and a large lag screw will secure those back legs to the slab. I contemplated a sliding proper dovetail, but there is a ton of glue surface here (although I may cut it at a couple of degrees for a little bit more mechanical strength).

The front legs, however, need to be more solidly attached to the top due to strain from the leg vise and the holdfasts. In my previous Stent Panel workbench, the legs were merely blind-mortised into the top. A friction fit, with glue and drawbores, made a very stout joint that was nothing special to look at. But that was last time. This time, we’re doing the Roubo tenon/sliding dovetail! All these years later!

The slab was blind mortised to attach the frame on the old bench. I plugged those old mortises with epoxy and a tight dutchman.

I’m not sure I agree that this is a simpler joint than a double tenon (i.e., where the front recess is also square instead of angled for the dovetail). Well, at least the mortise part. The dovetailed tenon is dead simple to cut, if a bit fiddly to get those little front shoulders in line with the center shoulders.

Just keep track of which leg is which through marriage marks.

But it does look nice, especially after a few wedges fill up any remaining gaps. I apparently cut one of the joints a bit too tight, as a hairline split emerged along the front of the inside tenon. I don’t think it will be structural, and it doesn’t appear to have gone all the way through the slab. The glue joints are large and sound, so we’ll see if I need to drive some lag bolts in to secure it.

It does look pretty nice, though.

I had never cut a double tenon before (sliding dovetailed or otherwise). I’m now satisfied that I can do it effectively now. But if I ever do this again, I know now to make it a bit less friction fit and let the glue do the work.

And knowing is half the battle.

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Back in the Swing of Things

After a decent hiatus, I’m back and exactly the same as ever! Seriously, I have one big project in the queue (a replacement dining table since my mother absconded with my old one), but instead I’ve been dicking around with the Moravian Workbench.

My first try started with a simpler design that any apartment DIYer with a miter saw and a basic set of tools (saw, chisel, drill driver) could build from home center 2×4’s. Having a basic Apartment Workbench would help, but it’s not really necessary. Just laminate the slab for the top first and use it as a worksurface.

I planed and squared the pieces before laminating, but you could get by with just sanding a bit as long as the stock is relatively straight and untwisted. The angled, through mortises for the tusk tenons were laminated into the legs as I went, which worked really well.

Probably too many clamps for this application.

To keep things manageable, the crossrails on each leg assembly were lapped in and secured with screws, rather than mortised in. This worked well on the lower and middle stretchers, but it was a bit dicey on the top stretcher and I think the bridle joint used in the original Moravian Workbench design would have worked better. In retrospect, I think using Spruce (instead of Douglas Fir) for the leg assemblies would work better for this DIY approach. Spruce is a bit softer and lighter, but still very stiff, and somewhat less prone to chipping out.

Douglas Fir can be pretty, though.

Like the leg assemblies, the joints on the long stretchers were formed with a longer middle piece to form the tenon and two shorter pieces with the angled shoulders pre-cut. Just use the same angle setting as you used for the leg assemblies. The only real joinery in this version of the bench are the mortises for the tusk tenons. I used a brace and bit, boring in from each side and paring down to the lines, but chopping is just as easy.

The long rails look a bit chunky, but it really adds some weight.

I didn’t end up laminating a new top for this. I repurposed the plywood slab from the Plywood Roman Workbench. This bench will live in the garage of a friend who has recently gotten more into DIY, so I may have gotten a bit lazy near the end. I didn’t make the back shelf, as my buddy has a kreg pocket hole jig and some extra plywood. It can be his first project on the workbench. I also didn’t make a leg vise for the bench. He’s got clamps.

Not winning any beauty contests.

So, all in all, this worked out just fine. It allowed me to explore the Moravian Workbench form without worrying about wasting more expensive lumber while I experiment.

And this practice served me well, as I make a second version that follows the actual design more closely.

But more on that next time.

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