Phase 1 : Cutting

Time: 5pm – 8:30pm
Task: Rough cut 4, 2×8’s to 16, 1 1#2 x 3 3#8 x 54 1#4

Took awhile and they ended up far from perfect but the best *I* could do with no table saw.
I started by cutting the 2×8’s down to 54 1#4 with my miter saw.

I then ripped 2#16’s off each side to knock off the round edges. One last rip to get 2, 3 3#8 boards.  I used the guide on my circular saw for the rips.

With wobbly saw horses and no ripping skills the final boards did come out with nice square corners, but no where close to flush when stacked face to face.  It may have been better to do the rips before cutting them down.

Looks like some serious planing is in my future.

Update (2016): My bench is now finished and if you’ve never done a project like this before and are at this stage, if you’re boards look anything like this, STOP. Stop, find a table saw, and do this step correctly. These need to be perfect because chances are you won’t do the serious planing you need.

Phase 0 : Workspace & Wood

Temporary Workbench
First to create some kind of temporary workbench.  I currently have this so was able to create at least a basic workstation.

The underside of the table however was an impossible clamping surface.

 

 

 

 

So I sawed off the front to make it flush with the top rail then took one of the shelves and drilled it up underneath to create a fairly flat surface.  I also knocked out the back a little so I could feed a clamp in from behind.

Not great, but it beats my previous sad excuse for a “workbench”…

Lumber
With the temporary workbench ready to go I headed to Spaeth Lumber and picked out 8 of their best 2x8x12 kiln dried Douglas Fir boards.  I choose Doug Fir because that’s as close as I could find to Southern Yellow Pine here in Oregon.  Kiln dried was a tad extra but seemed worth it to avoid the drying and flexing issues of green wood.

Workbench

Here is my attempt to build a workbench. I have almost zero woodworking experience (see the desk I built when I had zero woodworking experience) and have found that there is surprisingly little out there with the details, and step by step guidance I was hoping for. To put my woodworking level into perspective, prior to this project I didn’t know what a dog hole was. So if you’ve decided to embrace woodworking, have little to no knowledge of the trade and need a bench – maybe this will help.

A number of articles expect you to have machine planners and a table saw. I have neither. So everything I’ve done was done with some very basic power tools, and your basic hand tools.

Resources
Here are the main resources I used.  There have been numerous other articles and forum posts but these are the best I’ve found that I based my design off of.

Others
A few other benches that are based off of Bob and Dave Key’s.

Virtually every idea, concept or solution I mention in the following posts have come from someone else.  They deserve the kudo’s. I’m simply trying to consolidate everything I’ve learned with as much detail as possible for all the other noobs out there.

  • Phase 0 : Temporary workbench and lumber
  • Phase 1 : Cutting down 4, 2×8’s for the top

Homemade Custom DIY Ergonomic Computer Desk