I was getting my gap/stop from a twelve foot 2" x 12". After setting up the support at the bandsaw, I ripped the 2" x 12" in half. I had to be careful feeding the board to avoid binding or stressing the blade.
After ripping, I used my custom made winding sticks to evaluate the twist.
They're simply two pieces of 1" x 4" mdf. One has an edge painted black with a Sharpie and the other is the factory white. I have another piece about ten feet long that I use for setting up infeed and outfeed support.
I find if you use and place infeed and outfeed support correctly, it's not that hard to get the twist out of a board without loosing a lot of thickness.
I was a little off from the crux of the twist, but not too bad. You can see the progress in these photos.
Once jointed, I set up and sent the board through the planer. The entire process only wasted 3/8" of the thickness. I went from 1 13/16" to 1 7/16".
That left me enough to get the entire gap/stop from this half of the original 2" x 12". I went back to the bandsaw and resawed the board and again ran the two halves through the planer. I got to each being 5/8", which was perfect. There was enough material to get the five center dividers from this board, too.
This shot is from the next evening before I started working again. The old growth Fir is dry through and through. That has really been the joy in working with this old wood. It just doesn't move.
Here you can see what I find so special about old growth Fir. This old tree experienced some good droughts in Eastern Oregon. There is one section that had 4 growth rings within 1/16".
To keep things aligned during the glue up, I used the method I'd seen David Marks use on DIY Woodworks. For each divider, I tapped in two small brad nails and clipped them, so a nib was sticking up. Before applying glue, I aligned and pressed the assembly together, so when I did apply the glue the pieces fit and stayed in place as I applied the clamps.
The final step in the build for me was to make the sliding dog hole and all the dogs. The sliding dog hole was made the same way I made the other dog holes. After gluing up the board, it was simple to cut and fit to the Benchcrafted vise hardware on the bandsaw.
This seemed to be as good a time as any to go ahead and do the final flattening on the top. The finish I'd already applied made it easy to see my progress.
After creating a bunch of shavings, I had a dead-flat top. I took six passes diagonally and six more with the grain. I didn't worry about tearout, and there are still some planing marks, but it is flat.
I'm really happy that I installed the floor sweep on this side of the shop. Most of the mess I make on this side will always be able to be swept without putting dust into the air.
The process I used to "mass produce" dogs was first milling some stock to be close, but a little oversized for the holes in the bench. I ripped the stock first at the band saw, jointed, edged and thicknessed at the jointer and planer, then crosscut to length with the tablesaw sled.
A stop block on the bandsaw stopped the long cut on the dogs and the little "chin" was cut using a square piece of plywood for a guide.
I had some of the dog stock left and ripped some strips at the bandsaw. I only needed one side to be smooth for gluing, so I left the other side rough, figuring it would help keep the dogs in place. I cut the spring pieces to length with my 2" chisel and also put the inaugural chisel marks in the top at the same time. By clamping the dogs in the vise at an angle, it was extremely quick to put the angle at the bottom of the dog where the spring would be glued and screwed to the dog. A one man assembly line later and the dogs were done.
And THAT, my friends, concludes my participation in The Woodwhisperer Guild's Roubo Bench Build. This was, as always, more time consuming than I originally thought. I'm still getting the processes of building more efficient within my shop. This build changed the location of my bandsaw and opened up some other idea for changes. I'll get into those when I make a firm decision.
This is the completed bench:Flair Woodworks. After all, EVERYONE needs a Br'all!
Scott Meek. He's a very talented plane maker. This smoother is heaven to use. Be sure to support your boutique tool makers.
If after following this blog for the last few months, you're still jonesing for more of that bench building fever, check out these other fine people doing their versions of a woodworking bench. If I've missed anyone, my apologies. Contact me and I can add your site to this list.
And, of course, you can sign up for The Woodwhisperer Guild and learn from Marc Spagnuolo. Marc is taking the Guild through the building of this lifetime woodworking bench. With his usual easy delivery and thorough understanding of the process, he makes this very large project easy enough for the beginner, who has a very basic tool selection.
I hope you have enjoyed the building process. Woodworking is what I want to do until I die. It is what gives me peace and is my passion. If you think you may be interested in woodworking, contact me and I will try to get you pointed to a resource near you and/or online. Thanks for taking the journey!