Datasheet

one-day workbench
Forrn interlocking
slots
!
Make
the slot template, shown
on
* Drawing 1, from leftover particle-
board. To
cut the slot as accurately as
possible,
use a
jigsaw
and straightedge.
Mark
the outside corner, where
shown.
{}
Retrieve
one of the ends
(C),
and
&r clamp the
template to
it,
aligning the
template's marked
corner with one of the
part's
corners.
Chuck a %" flush-trim bit
in
your
handheld router,
and rout the
slot, as shown in Photo B. In
the same
manner,
rout the other three
slots,
where
shown
on
Drawing 1, flipping
the tem-
plate
as
needed.
QUsing
it as a template, clamp
the
tf slotted end
(C)
in
turn to the other
part
C and the iwo
left
bases
(B),
and
rout
the slots in those
parts,
where
dimensioned
on
Drawing
1.
Rorrt,
drill, slot,
Iinish,
and assernlele
I
Chuck a
t/s"
round-over
bit in
your
* handheld router,
and rout all edges
of
parts
A, B,
C,
F,
and G. On the long top
(D)
and short top
(E),
rout all
the edges
except where the two
tops butt together,
where indicated
on
Drawings
1 and 2.
With the slot template
(painted
green
for
clarity in this
photo) guiding
the flush-
trim
bit's
pilot
bearing, rout
the slot
in
the
end
(C).
fjN
Drill 7-r:" countersunk
shank holes in
#l
parts
D, E, F,
and
G,
where
shown
on
Drawing
1.
Q
nOiust
your
biscuit cutter
to center a
tJslot
in the
thickness of the
particle-
board. Plunge mating slots in
parts
D and
E, where shown. Biscuits
inserted wirlz-
out
glue
in the
slots
keep
the tops aligned.
tlTo
protect
the bench from moisture
-f
and
grime,
apply two coats of finish
to all the
parts
before
assembly.
Apply
a
third coat to the top
after assembly.
To
keep
the cost down,
you
can use any
house
paint
or
finish
you
have around.
(We
used satin
polyurethane.)
Hwith
the finish dry, enlist
a
helper
dand assemble the bench, as shown on
Drawing 2
and
in
the four
photos
on
page
82. Take care in handling
the bases
(A,
B). The
6"-wide
"rails"
are somewhat
fragile
until the bases are interlocked and
supported by the ends
(C)
and shelves
(F,
G). Using the
previously
drilled
shank holes in
parts
D,
E, F, and G as
guides,
drill
pilot
holes in
their
mating
parts,
and drive
in
the screws.
Add
the optional shelves
T
To add shelves
to the ends of
&
yor.
workbench, where
shown on
Drawing 2, cut the long and short cleats
(H,
I)
and shelves
(J,
K) to size.
Corttined ou
puge86
No round-overs
{-====
#8 x2"
F.H. wood screws
E
EXPLODED VIEW
^
r/ti"round-overs
%x
#8
x 11/2" F.H.
wood
screw
t/e"
round-overs
along
all edges
#8x11/q"F.H
wood
screw
#B x 2" F.H.
wood
screws
t/e"
round-overs
along
all edges
t/e"
round-overs
on
front
edges only
4-#20
biscuits for
aiignment
countersunk
(Do
not
glue.)
84
WOOD magazine November 2002