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Old 12-26-2009, 10:13 PM   #406
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Gulf Island Building.


Several minutes after cleaning the glue off, I noticed there was more running down the side. So I cleaned that off as well. This kept up for some 15 minutes before finally stopping.
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Old 12-26-2009, 10:14 PM   #407
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Gulf Island Building.


Two thirds done.
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Old 12-27-2009, 12:44 AM   #408
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Gulf Island Building.


The woodworking gods were smiling upon me when the last section went together. Smooth as silk. I was very careful with the glue this time, just enough, not too much.

Of course, as usual, I couldn't find all my long clamps. But there is a small amount of squeezeout right along the top, so all should be fine.

Not a bad looking top. It ended up 24 9/16" wide. Heavy though, I can't pick it up any more.

Tomorrow I start to tackle the underpinnings.
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Old 12-27-2009, 05:59 PM   #409
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Gulf Island Building.


Cleaned off the very minor amount of glue both front and back on the benchtop.

Then started to stand the legs, each of which has turned out to be a nice tight fit in their respective mortises. I may have to shave a trace off before the glue-up, we'll see.

In order to cut the stretchers to length, I pushed each leg part way into the mortise. Stood each square to the top using the framing square, after which I could measure the length of them. The stretcher mortises are 2 1/2" deep, so 5" was added to the length of the inside dimensions of each stretcher to make sure the mortise was filled. Actually, I knocked 1/16" off the length, just in case too much glue got in the hole. I have seen the case where the joint was tight, and with glue applied the air trapped in the hole made it nearly impossible to seat the tenon.

In order to alleviate this, I think I might cut a small groove down one side of the tenon, allowing the air and any excess glue to escape.

Here we are setting up the leg, which is party pushed into the mortise.
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Old 12-27-2009, 06:03 PM   #410
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Gulf Island Building.


Here the legs are pushed an inch or so into their mortises. The stretcher stock was cut using the actual dimensions taken from right between each pair of legs. 5" was added for the inside stretcher (each stretcher has both an inside and outside piece).
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Old 12-27-2009, 08:48 PM   #411
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Gulf Island Building.


There is a fair bit of work required before glue up can commence. Each leg needs the second mortise drilled out and cleaned up. The top of the outside front stretcher will be chamfered 45 degrees on each side. This will be to accommodate the groove in the sliding deadman - more about that later.

And the left front leg will require a slot in the bottom which will accommodate a parallel guide for the leg vise.

In the original bench, Chris used pegs driven into drawbored holes and no glue. The thought being that if he ever needed to take the bench apart, the pegs could be drilled out and voila - instant top removal.

Since the chances of me ever wanting to do that are zilch, mine will be glued.
First go round I drilled the holes using a forstner bit.
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Old 12-27-2009, 08:51 PM   #412
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Gulf Island Building.


I was less than impressed at what a pain it was, so the next time I chiseled out about 1/8" of the mortise first. It was much easier to drop the drill bit into the mortise and go from there.
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Old 12-27-2009, 09:48 PM   #413
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Gulf Island Building.


Once that was done it was easy to use the side of the shallow mortise to guide the bit with.
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Old 12-27-2009, 09:54 PM   #414
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Gulf Island Building.


After drilling the bulk of the mortise out, the hole is cleaned up with a sharp chisel.

One thing I have found useful is to test the fit with a cutoff from the stretcher. Rip part of the board off so that it is not quite as wide as the mortise. In this way, as you test the fit, you can determine where - if anywhere - there needs to be any adjustment.

If you try a full size piece, it is more difficult to tell where any tight spot might be.

Here is the test piece at both ends of the mortise.
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Old 12-30-2009, 01:30 AM   #415
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Gulf Island Building.


The short end stretchers are identical, but the front and back are different. There is a guide on the front stretcher for the sliding deadman. It is similar to the outer board on the back stretcher, except that it is chamfered for the deadman to center itself by gravity.
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Old 12-30-2009, 01:35 AM   #416
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Gulf Island Building.


In the book, Chris admonished against using an electric hand saw (yes, the one you all wrongly call a skill saw) with the blade set at full cutting depth. No matter how butch your saw may be it will burn when cutting at that depth, therefore several passes should be made.
Finally something we can disagree on. I used a fairly light Ryobi (12 amps) with a new blade. All you need to do is to cut slowly and watch that you are following your thin pencil line exactly.
Nothing to it, no burn - in fact the motor never even slowed down.
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Old 12-30-2009, 01:38 AM   #417
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Gulf Island Building.


Here's both the front and back stretchers. You can see the support rail for where the shelf will rest.
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Old 12-30-2009, 01:40 AM   #418
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Gulf Island Building.


After the ends were trimmed, I decided to add skirts. I chopped up some arbutus for this, mainly because I had some here. Here is one end being test fitted, held on loosely with biscuits.
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Old 12-30-2009, 01:43 AM   #419
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Gulf Island Building.


About the last machining operation on the underside of the bench top was the guide for the deadman. A plunge router did the job cutting about 1/4" at a time. Now, here is a case where several cuts are far better than trying to do the whole thing in a single pass.
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Old 12-30-2009, 01:46 AM   #420
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Gulf Island Building.


Before the skirts were attached, I drilled countersunk holes for the lag screws. Quite small lags, just 1/4" by 4" long. More than enough with the biscuits and glue to do the job I think.
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