Workbench Build #10: More on the vise end cap

  • Advertise with us
Blog entry by Mark Kornell posted 11-25-2014 06:00 AM 3087 reads 0 times favorited 3 comments Add to Favorites Watch
« Part 9: Vise End Cap Part 10 of Workbench Build series Part 11: Wagon Vise Install »

Trimming the tenon cheeks and shoulders was fairly straightforward. The hardest part was flipping the 200 lb slab every 5 minutes…

There were two issues. First, the tenon shoulders weren’t coplanar. In fact, they formed a kind of X. I doubt my collar jig was that bad, so I’m inclined to think there was a lot of flex in the circ saw, and probably exacerbated by the blade burning issue.

The second issue is that the tenon depth was uneven. That’s a layout problem.

It was probably too much to ask to get a perfectly cut tenon from a circular saw, anyways, so I’d recommend planning on trimming/squaring it up from the start.

Here’s the non-coplanar issue:

I have a track that clamps across a board and has a slide I can attach to my router. So I figured out the relevant offsets and carefully laid out a square line across the slab at the desired location. Because I need to do this operation on both sides, I extended the layout lines down the sides of the slab, too. Then I clamped the track on the line:

Set the plunge depth to a hair less than the shoulder depth. The tenon is already trimmed to width so I don’t want to touch that. I’ll use a chisel to trim off the little sliver I miss with the router.

The first trim:

A little bit of tearout in the middle where I attempted a climb cut. D’oh! And that’s the top :-(

I was very careful when I extended my layout lines across down the sides. I need to flip the slab and reset the track on the other side. I then had this idea that I could clamp squares in place to register the track against after the flip:

Surprisingly, that worked perfectly. I removed the track, carefully flipped the slab and gently reset the track. Looked like it lined up, so I went for it. Dead on. No pics, you’ll see the fit later.

The next step was to trim the tenons to depth. I have an adjustable edge guide jig I use with my router, and I started with that. I removed the adjustable part and attached a fixed-depth fence. Nothing special about that, just a piece of scrap plywood cut to the right width. It was set to just touch the router bit.

And here’s how it looks poised for action:

Set the plunge depth to half way, and take a pass:

Flip the slab, do the other side. The end cap fits perfectly, no need to undercut anything.

I got a start on fitting the vise hardware. That’ll be the next blog post.

-- Mark Kornell, Kornell Wood Design

3 comments so far

View CL810's profile


3959 posts in 3472 days

#1 posted 11-25-2014 01:31 PM

That turned out nice! You’re making me want to build another bench, lol!

-- "The only limits to our realization of tomorrow will be our doubts of today." - FDR

View RoadHogg's profile


127 posts in 2411 days

#2 posted 11-25-2014 03:02 PM

Nice work. Kinda hard to have a “test piece” on such a large scale project so every cut is a live cut. Kinda working without a net. I still admire your work.

-- "The difference between school and real life is that in real life the tests come first, and then the lessons" -- Robert Lang,

View Mark Kornell's profile

Mark Kornell

1170 posts in 3015 days

#3 posted 11-25-2014 06:23 PM

I think of the workbench as one massive test piece. Test run for the next one. Probably need to build 5 or 6 to get good at it…

-- Mark Kornell, Kornell Wood Design

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics