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I was looking in my big template drawer for a 36" radius pattern the other day and couldnt find it. I ended up emptying the whole drawer including the 1/2" of dust on the bottom of it. I did find the 36" radius and this stack of leg patterns for our Egyptian leg. I think I made the first one back around 1988 and have done, (it seems), many, many variations on it since. More Egypt leg pieces here ....

So Im building a bench. I know thatll come as a shock to many of you, but I too need a place to build my projects on.

The boards milled & rabbeted, ready to be cut to lenth.

Im beginning with the stretchers - or as Im making - panels. In order to construct the leg assemblies with as little a chance of racking and as much mass as possible Im forgoing the normal stretcher assemblies and using a bastardized frame and panel design. The frames, and much of the bench, are made of Timberstrand (dimensional lumber made of OSB).

I began by milling the Timberstrand just as I would any other lumber. A few quick passes on the jointer, a pass or two through the planer, a final trim on the table saw and voila, flat & square boards. In order to make a dado (yes, I know its actually a grove) in the middle of the frame pieces, I instead made a rabbet in two frame pieces and assembled them to make a dado. As Ive was holding out for a Forrest Dado King, I made the rabbet using two passes on my standard Woodworker II blade. As the panel will be composed of an MDF/OSB lamination, I used relative dimensioning to set the depth exactly to each sheet goods thickness (they are actually not the same thickness, even though theyre both nominally 3/4" thick). I then turned the board and cut the width of the rabbet to the same dimension as the depth (it wont matter if one sheet good panel is ever so slightly bigger than the other, theyll be cut via relative dimensioning too).

Gang cuts = perfect fits.

My next step was to take them over to my new Bosch Glide saw (no full review yet, but its kickin ass & takin names). I cut one end on each board, ganged them and cut them all to the exact same length. I then used my Domino to join the frame panels. Woodpecker Clamping Squares helped keep the whole thing square.

Now that all the frames are made my next step is to cut and fit the panels, then glue an OSB frame & panel assembly to an MDF frame & panel assembly to make the final, bastard frame & panel assembly I plan to use. Then Ill have to finalize the legs and start thinking about the top. Much to do.

Ready for the panel.

Heres the whole album.

How did you attach your bench legs together?

p.s. - Sorry for all the linking, I got a bit carried away. I also just picked up a FlipHD, so heres a video of the fames to boot.


Wookbench Stretcher Panels from Dyami Plotke on Vimeo.

I have the shape roughed out and ready to fine-tune. I am not going to remove any more stock until the pin is holding the two plates together, even though I have to fight to get the barrels lined up right now. For the first time in my life I was really stingy with the material I removed, so instead of having to figure out how to add material to overcome a sloppy fit (something I still haven’t figured out after all these years), this time I have to refrain from removing more to make the joints freer.

The hinge is 20” long and 6” wide, each plate being 3”. The hinge flats are ¾” thick and the barrel is 1 ½” in diameter. I have a ¼” brass threaded rod that will act as the pin, held in by an acorn nut with twin shoulder washers on each end. Drill the ¼” hole, slide the pin in and Bob’s your uncle (he is, actually – God bless him).

I have been putting this little drilling job off now for two weeks.

So what’s the hold up?

That 20”!

I’m scared to death that I will not get the bit aligned right, especially because I will have to drill from both ends and meet in the middle. If that isn’t enough reason to stall the job, I can always add the reality that a ¼” drill bit travelling 10 or 11 inches is definitely going to have some deflection along its way, so even if I get the alignment bang on, how can I be sure the drill won’t decide to head south a quarter of the way through?

Any ideas?

Peace

Mitchell

It is a beautiful morning today ...


On the CA Central coast most of the summer mornings are very foggy, hopefully today is a sign of sunshiny mornings to come!

Yesterday was spent sanding and priming a few pieces, but before I show you those here are some updates to our "fall" patio.

I know my colors arent exactly fall appropriate, but I couldnt find reds, oranges, and yellows that met my part sun requirement, so I improvised!  


Im not much of a gardener and everything that I planted at the beginning of summer in the two planters died ... I guess the fact that the railing is plaster doesnt help, I had shade plants there but they never did very well. Maybe the wrong fertilizer?

So I decided to plant one of my favorite flowers, pansies! I was able to find a part sun variety at Home Depot, since it does get some late morning early afternoon sun, I am hoping that they will do well here.

I have a fondness of pansies from my Grandparents house in South Carolina, my Grandfather, an expert gardner, had a long curving walkway with large beautiful pansies on both sides brimming into the walkway. Hopefully, mine will be flowing out of the box soon!





In addition to pansies, I planted astors in the ladder planter

I know my colors arent exactly appropriate for fall, but CA has all kinds of flowers year round, so I figured I should enjoy while we are here!

Happy Friday! I hope you have a great weekend!