Lag Bolt Workbench

OVERALL DIMENSIONS (with fence): 411/2H x36Wx23D

1V16X 13/4-36 3/4 x 13/4 - 36 3/4 x 13/4- 18 3/4 x 2 V2-36 3/4 x 1 3/4 - 8 1V4 x 13/4 - 27/8 '/8 hdbd. - 7/8 x 1 Va frame and accessories

5/l6"-I.D. THREADED INSERT

3/s" PLASTIC KNOB

Vie" x 2Va" THREADED KNOB

hardware supplies

(8) No. 8 x 7/8" Fh woodscrews (12) V4" x3V4" lag screws & washers

(2 pes.) 23V2" x30V2" plastic laminate (4) L-shaped mounting brackets (4) 5/i6M inside dia. threaded inserts (4) Vi6" x 2V4" threaded knobs & washers

(2) 3/g" x6" carriage bolts

(2) 3/g" plastic knobs (or wing nuts) & washers T-slot nuts (for accessories, see pages 70-71)

CUTTING DIAGRAM

Va" HARDBOARD - 48 x

Va" HARDBOARD - 48 x

2x4 (V/2 x 3V2) - 8 Ft. (Four Boards @ 5.3 Bd. Ft. Each)

OVERALL DIMENSIONS (with fence): 411/2H x36Wx23D

5/l6"-I.D. THREADED INSERT

3/s" PLASTIC KNOB

Vie" x 2Va" THREADED KNOB

Shape Fence Mounting Brackets
2x4 (1V2 x 3V2) - 6 Ft. (4 Bd. Ft.)

c

c

C

1 ' ' ■ ™ 1 -1 ..•;..; ,.'////////////////////

3/4 x 5V2 - 96 (3.7 Bd. Ft.)

j

L

L

J

K

1

K

M V//////////////Á

y/////////////////////////////////////////////////////////////////////////////////////////////////

1% x 3V2 - 48 (2.3 Bd. Ft.)

V//

/////////,

1/

Y/yyyyy// //////////

Exploded View Woodworking Bench

FRONT

3/4"x 3" HARDWOOD DOWEL

Va" x 3 Vi" LAG SCREW

LEG PIECES

STRETCHERS

CUT DADOES TO FIT RAILS

NOTE:

RIP ALL 2x4 STOCK 3" WIDE

RAILS

CUTTING DETAIL

VIEW

All you need to build the base is four 8 ft. 2x4s and a 6 ft. 2x4. But before I started,

1 cleaned up the 2x4s a little by ripping Vt" off each edge, reducing the width to 3" (see Cutting Detail in Fig. 1).

end frames. The base has two end frames, each consisting of two legs and two rails. Each leg is made from two 2x4s. These leg pieces (A) are cut to length and then sandwiched together in pairs (Fig. 1).

To simplify the joinery and provide mortises for the rails (B), I pre-cut 3"-wide dadoes and rabbets in each leg piece before gluing them together.

After these cuts are made in the leg pieces, glue the legs and rails together to complete the two end frames (Fig. 2).

stretchers. Next, the end frames are joined together with three stretchers (C), also made from 2x4s.

Note: To provide access to the router, there isn't a top stretcher between the front legs.

The stretchers are fastened to the frames with lag screws. But since these lag screws are being threaded into end grain, there's a trick I decided to use to help strengthen this joint.

I drilled a 3/4" hole, l1/«" from the end of each stretcher and glued a dowel into each hole (Fig. ■>). The cross grain of the dowel holds the screw firmly.

assembly. Finally, assemble the base by joining the end frames and the stretchers with W x 3'/.i" lag screws (refer to Figs. 1 and 3).

Exploded Table Top

I began making the table top by cutting a base (I)) to size (21 W->" x 2872M) from 3/-i"-thick plywood (Fig. J,).

The next step is to cut two slightly oversize covers (E) from Vi" hardboard and glue them on top of the plywood base with contact cement. Then use a flush trim bit (as shown on page 16) or a pattern bit (as shown in the Shop Tip below) to trim the hardboard flush with the plywood.

edging. Now the the whole core section can be edged with hardwood. I used :W'-thick maple edging (F, G).

First, rip the edging to match the thickness of the top (Fig. 5a). Then cut it to length (Fig. 5).

Now, glue and clamp the edging pieces so they're flush with the edges of the top. When the glue is dry, sand or file a radius onto each corner (Fig. 5b).

laminate. The last step is to glue plastic laminate to both the top and bottom faces of the table top (Fig. (>).

Note: It's important to glue laminate to both faces. This will help prevent the top from warping.

Here again, I cut the laminate oversize, then trimmed it — but this time with a chamfer bit to chamfer the edge of the top at the same time (Fig. 6a).

finish. Before going any further, I finished the base and edging with a tung-oil finish.

srasp hop

Wood Working for Amateur Craftsman

Wood Working for Amateur Craftsman

THIS book is one of the series of Handbooks on industrial subjects being published by the Popular Mechanics Company. Like Popular Mechanics Magazine, and like the other books in this series, it is written so you can understand it. The purpose of Popular Mechanics Handbooks is to supply a growing demand for high-class, up-to-date and accurate text-books, suitable for home study as well as for class use, on all mechanical subjects. The textand illustrations, in each instance, have been prepared expressly for this series by well known experts, and revised by the editor of Popular Mechanics.

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