My first Bench On Bench was delightful. It brought carving and joinery tasks to a very comfortable height. Two and a half years later, I still appreciate it, but know of ways to improve it. The most wanted improvement is better work holding capability for carving work. Pinching stuff between dogs in the front vise and the “floating planing stops” just wasn’t working well enough. Shims of various sizes were almost always needed. The front vise itself grew to be a bit floppy, the result of installing the vise screw nuts loosely in softwood sockets. As they floated and wiggled around, they also wallowed the sockets. The best part about the bench was the vise screws, 1/2 inch veneer press screws that were available several years ago from Tools for Working Wood, but are not to be found anywhere today. The handles on those screws can be pulled out and rotated, very convenient for moving them when “tight” leaves them sticking up in the way. Those are keepers! Lastly, the excellent Gramercy holdfasts were rarely useful due to the smaller size of most of my work pieces.
Along comes Chris Schwarz with the “Milkman’s Workbench.” Intended as a portable bench, it has a few features I like and thought would be useful. In the end, I borrowed a few ideas from that bench. The first was lamination from maple instead of fir. This is the last workbench I’m going to build; I might as well use hardwood. The next feature was the wagon vise. However, I’ll use another veneer press screw instead of the wooden screws. I can’t justify the tooling cost for making just one of those wooden screws, and for what it costs to buy one ready made, I can buy a couple of top of the line carving gouges. The last feature was square dogs and their recessed self-storage. I’ll keep the full width front vise and the excellent screws with adjustable handles. I find that vise better suited for the way I work.
One of the nearby home centers actually carries maple. It’s “mystery maple” since the specific variety isn’t identified. There was some minor spalting in two of the three best boards. My right thumbnail Janka gauge determined the stuff was OK. That’s the discoloration seen in a few spots. Even though the specific type is unknown, it was straight, free of knots and a joy to work.
Yes, it is a lot harder than most stuff I work with, and yes the Record 044 didn’t want to plow a 1/2 inch groove without a bit of help, and yes, cranking a 1 inch auger through it with an 8 inch brace was a bit of work. Yet, it is remarkably predictable and finish planing leaves a glass like surface.
The new veneer press screw doesn’t deserve nearly as much praise. It is advertised at most all woodworking supply sources and out of stock in almost all. Once acquired, the threaded socket that is advertised as a “1 inch press fit” is found to be an elliptical shape with ribs on the side and must have been the seventieth son of the seventieth son to be so asymmetrical. There’s enough play in the threads to never have to worry about them seizing, but maybe that’s why they hold a setting so well. Fitting something like this is when one learns to really appreciate how well Michel Auriou’s rasps perform (the one on the right, not the rat tail).
About 3/4 of the way through gluing up the pairs of strips that accommodate dog holes, I remembered that some of my working methods really want clear space on the right end of the bench. Actually, I find myself doing several operations that overhang the right side. Oooops, that vise screw is going to be in the way. OK — Plan B! Just flip it over … and smooth finish the bottom side … and make some more dog recesses.
The rest is a matter of careful assembly, lots of gluing and clamping, lots of planing, a bit of drilling and fitting. By the way, the entire project was done with only hand tools. No electrons murdered. No sandpaper martyred. Very sharp plane blades, and well groomed card scrapers gave excellent results. There’s only one area not completely finished. I did not glue the end block for the vise. It is temporarily fixed with press fit Miller Dowels. It is the dry season now, about 25% humidity. In late summer humidity goes to 90%. I’ve left this area free of glue in case it needs to be disassembled and adjusted.
Update: I forgot to mention dimensions in the original post. The bench top measures 31.5 inches by 18.5 inches. The top surface is 8.5 inches above whatever it sits on. It weighs 32 pounds.
The work holding capability is better than I aimed for, and the fit and finish is a big step above the previous version. All of the methods I practice can now be done easier and more reliably with this bench. There’s a slideshow below this last group of photos. It has a few more photos with explanations. As always, click on any photo to see a larger version.
The first Bench On Bench worked well and taught me what improvements it needed.
Start with 3 boards 1x6 by 8 feet. Rip each into thirds. Then, crosscut into thirds. The color streaks are from spalting.
Plowing 1/2 inch grooves used more than one tool, and a good bit of patience. The 044 plow plane was good at removing waste, but only after the groove sides were cut ahead. Maple is hard.
Checking the layout. Yep, that'll work.
Turning a 1 inch auger, in maple, with an 8 inch brace is near insanity. My 10, 12, and 14 inch braces are still on the 'buy someday' list.
All parts catalogs say this is a 1 inch force fit. Yeah right! Asymmetrical, winged, and tapered. Lots of fussing... The Auriou rasp is superb!
Ahhhh. Vise dry fit #2. Now, it looks like a vice. Those walnut pins are the garter, temporary for now.
All the parts ready for assembly ... in 'Plan A' configuration.
Do this 6 times over the next few days, or go buy 50 more clamps. :)
Nuts for the front vise screws are mortised in very snugly, and then epoxied to prevent any wiggle.
Plan A - Traditional, with wagon vise on the right.
Plan B - Flip it over. Wagon vise on the left and better use of the right end of the bench.
Scrub baby, scrub! I have an alternate curved iron for the #5. Maple is hard, but predictable, and finishes very nicely.
Miller dowels through the bridle joints make the vise strong enough. Nothing here was glued for now. It's the dry season and may need disassembly when the humid season arrives.
Work holding - a typical relief carving
Work holding - a larger and scarier relief carving - space for much larger...
Work holding - This one is hard to hold well, but this works, a good test for moderate sized 'in the round' carvings.
Work holding - typical joinery cutting - 22 inches between vise screws gives lots of capability.
Work holding - on the bench surface - plenty of capability for my scale of box making
Work holding - Needed a slight overhang. Easy. Drop the left end of the front chop and use the wagon vise. Easiest grooving ever.