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#1 ·
New jaws for an old Workmate type bench

New jaws for an old Workmate type bench
Outdoor workbench for the allotment house.

Hi there,

This little blog series, will be about restoring and making upgrades, for Workmate type benches.
Not that I'm a big fan of them, in fact I used to laugh at them…, but I have come to realize, that they DO have their place, especially for the armature woodworker, who are doing house repairs, as a real workbench NO. They should be called work tables, not work benches, as work benches they only have a place in hell, laugh.

Its been a while since I was last on LJ, life is sweet and busy, health is good, even I have quite a lot of pain these days, coming from my operated neck, but I have nothing to complain about, now where we are under the pandemic and I spend as much time as I can in my tiny house, building, repairing, fixing, making and gardening, so as a retired, the crisis are just a period without hugs, besides that, its much the same But I send my best thoughts, to all the families that lost a member, due to this little virus, that has changed our world as we know it.


Some of you know I bought an old allotment / tiny house and with this came not just one, but two workmates, one of them an original, with flip up legs, so it can be used low and high, this is really cool with my old table saw on top. The other is a copy cat, its the copy cat I will give new jaws, as they seemed to have been outside in the rain once to may and MDF dont really like that…
But as you see on the picture, two of these and a generator, makes a wonderful little outdoor workshop, on this picture I make panels for the house, out of recycled materials.


Just so you know what we are making, here it is, the copy cat with new jaws and even a router table attachment, to put on top, but this will be for a later blog.


In fact some of you might remember I had one of these before
Yes it was back in the Paris days, I bought one to have in my GF's apartment, I was missing woodworking, when I was there. Laughs.
(I were in Paris 56 times in total, during those years often ten days at the time).


Yes my little Paris workshop.


Even cut French dovetails, with good red wine.


But that story came to an end.


Back to the story MaFe!!!
At the allotment, using the workmate with my Circular saw jig, for 90 and 45 cuts, but in fact I have used it a lot there, since its wonderful to work outside in the sun and my big Scandinavian bench are not easy to carry outside, smiles.


New Jaws MaFe!
Yes here cutting some plywood, its left overs, from a project I just did with my daughter.
Just same width and length as the original.


Then 45 cuts for holding tubes and pipes, yes even my smoking pipe can fit in there.


Here the old jaws, this is what happens when MDF meets water.
But as they have been used a lot, I think they have served their purpose.


Marking up for the holes, using a gauge, to avoid measuring too much, since this will increase the imprecision.


Marking up for the holes.


Again transfer and not re measure, jaws put how they will be on the table, then any fault will be on both jaws, in the same way.


Boards taped together, so it will not move.


Now try to hit the centre as good as your eyes will let you.


So the Forstner bit will be guided, when you drill it.


It went well.
Drilled almost through, so the centre of the bit came out, then from the other side, like this I got zero tear out.


Tadddaaaa, we got jaws!


Marking up for where they will be mounted on the back side.


Front.


Im not happy with the sharp edges on the holes, this will make a tear out, when taking bench dogs in and out.


So the get a 45 round over.


Using the new cordless Makita router I love that thing!


A pair of stretchers to put under, so the jaws can take some serious beating.
Since this is made in my real workshop, I cant cut them to length as the workmate is in the allotment.


I also grind the end stop of a pair of clamps.


So they can be used on the jaws, to stick through the holes.


Back in the allotment, the copy cat was put outside.


Yes they are well used or shall we say, used well…


Better?


The table were put upside down and the jaws could be attached.


Fresh screws.


It was put to use right away.


I never owned one of these before, we have not had a tradition of using them, but Hultafors has started making them and I love it together with the cordless circular saw, so fast and easy to make straight cuts.


The stretches were fitted to the possible length and screwed in place.


Clamps are super useful and easy to use.
So I'm a happy monkey.


And monkeys hang out.

See you soon, for more on this workmate series.

Hope it can be to some inspiration.

Best thoughts,

MaFe
 
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#2 ·
Always nice to see a workmate being loved. Somehow though, I think mine is beyond saving now. I think of it more now as 'living art', a reminder of the happy days we spent together before I had a workshop. May it rest in peace. Mind you Mads, I think you might have replaced your jaws a bit early. Mine has sat outside all year for the past 15 years and I was still using it last year. LOL.

Wood Outdoor bench Outdoor furniture Grass Musical instrument
 

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#3 ·
BTW - I sent you a package this morning. They couldn't tell me how long it would take to get to you though with the current disruption to both our postal services. I sent it to your Copenhagen address.
 
#4 ·
Hi Andy,
Wauuu that is a tired Workmate!
Beautiful in it's own way, like a old left Ford T car.
Ha ha ha.
The one I made new jaws for is a chepo China model, so the jaws were also chepo China material. I think you can buy these types for app. 20 gbp / 25 usd, so I restored it only for the fun of it, not to save money, just felt that it belonged to the house, so I would like to keep some of the atmosphere - a act of respect for history.
I think yours is from the old days, where they were made of better materials (the days where American made, was a quality stamp), the modern original Workmates can't stand outside for a summer, then the top will be trash.
Whoooooou!!! a pack… Now I'm really curious. Big smile.
I just received a pack from England, so it does work.
Big smile my friend, sad we can't meet up now, but we will when this pandemic is over.
Best thoughts to you and the family, send my love,
Mads
 
#5 ·
Nice rehab of the workmate, Mads. I am still using mine frequently as I get my shop with the real workbench set up. It sees a lot of work with the cordless circular saw, and I will probably need to make new jaws for it once everything else is up and running.

I mean to make a circular saw jig like yours, but don't have the materials for it on-hand, and don't want to make a trip to town for them, so I have been thinking about the issue and may incorporate something into the new jaws for my workmate. It seems like making that into a dedicated cutting station might work well once I'm more set up.
 
#8 ·
Just as I said in a recent post, I hate to see a tool go to waste. You've given some continued life to what others may have discarded. I think that's great. Some people restore tools because they want to. Others, myself included, do it because we have to. I, along with countless others, have been out of work for quite a while, so I'm very keen on the idea of tool reclamation and restoration. I simply don't have extra money to buy new tools so I have to find and fix what I can. I applaud anyone who is willing to take the time to give care and attention to old tools. Good for you Mads, good for you!
 
#11 ·
Circular sawing top for Workmate type benches

Circular sawing top for Workmate type benches
Outdoor workbench for the allotment house.

Hi again,
This time I was back fast. Laughs.

Now with a simple 30 minutes project for the workmate.
Just some some fixed replaceable rafters, that will support wider boards and that you can saw into, with the circular saw, without damaging the jaws.


Cut three or four roof rafter to length, you can make them even wider, but mind the stability.
Also three short pieces that are a wee smaller than the with of the jaws maximum opening.


Then make a T profile, that match the thickness of your workmate and screw that to the back of the rafters.


That's it!


Now you can saw boards and not worry to destroy the workmate.


The one in the middle is made a touch more narrow in the T, like this I can move it freely, while the two outer are secured.


Here you see how the bench holds it in place.


You can place them where ever you want.


Here cutting a piece of board, app half a sheath, it works just perfect.


Notice how I cut through the board and into the rafters, once they get too bad, they can be replaced in few minutes, while keeping the T's.
I marked them, so I don't have to look for that middle one.


Now sawing for the next blog project…


When the sun is shining, it's better to be outside, but the rafters will stay inside, until they are needed.

Thanks for watching.

Hope it can be to some inspiration and save some workmates.

Best thoughts,

MaFe
 
#19 ·
Table top for Workmate type benches

Table top for Workmate type benches
Outdoor workbench for the allotment house.

So here another 30 minutes or more project for the Workmate, a simple table top, so you will have a bigger surface, for projects, drawing, cutting or what ever you need.


First cut your self a table top of desired size, mine is app. Four times the size of the workmate top open.
From ply in same thickness as the Workmates jaws, cut two pieces, that are a a wee smaller than the with of the jaws opening and what ever length you fancy.
Also two pieces that are app 2 cm, less wide.
(You will understand soon).


Now glue the narrow pieces to to the table top, on the centre line.


Finally the wider, that fits between the jaws on top and put screws in, they should have a length, so they don't penetrate the table top.
You can put some 0,5 - 1 mm veneer or cardboard as a spacer on top of the narrow pieces, to make it easier to unclamp the table, mine locks up quite tight.


Look how the saw top things saved the jaws.


Here you see how the jaws lock the table top in place.


The Workmate table.


In fact I had one before, in Paris, years back.


For strength and to avoid warp, I put a pair of stretcher under.


Just like this.


From the under side.


Finally the top, after I gave it two coats of lacquer.

You could also glue polystyrene on top and use it for the circular saw…

It was last one today, next time it will be the router table top, but that's a wee more complicated.
The edges were rounded with a palm router, just for comfort.

Hope it can be to some inspiration.

Best thoughts,

MaFe
 
#28 ·
Router table top - can be used for Workmate type benches

Router table top - can be used for Workmate type benches
Outdoor workbench for the allotment house.

So last part of the Workmate series for now.

Yes I know Workmates are not sexy, Workmates don't come with any street credit with the wood guys and yes I can kind of understand if some one is thinking; 'a Workmate? This guy got all the best tools, several workbenches and then he talks about a Workmate!'.
I find a few things important when we write about woodworking, first of all to tell a good story, no one is interested in you bragging about your skills or project, go to your mother if you just need that, besides that you should try and remember that those you show projects to, might not be on the same level… Remember that you were once proud, when you could cut a board relatively straight, where you might now be at a level, where you get disappointed if it's not perfect.
Don't quite know what I try to say here, except that we can always learn something, it might be a little detail in the way it's done, a new technique or just a mirror to a different life style, where we can see our self in a new light and this is all I'm hoping for.


Here it is, the good old Workmate, with fresh jaws and now the router table top, that I will be making with you here.
The table top could of course just be made bigger, so it could be used as a real router table, or even smaller, so it could be in a big tool bag and be clamped to a table top on site.


Let's get started, back in my workshop.
Cutting some square pieces, that are app 2-3 cm / 1 inch, bigger than the base plate of the router I will be using.
Some 6mm acrylic one of my friends came with one day, he found it in the trash and thought I could probably use it, even it was quite a fancy color - he was right, thank you Flemming.


As I had decided to make it a Workmate thing, I decided that it should match the design and dimensions, so I made it same length as the jaws and the with was just as small as possible, while useful.
Sadly the jaws on the workmate are so tight, that I could not make it fit in between and so it has to become an on top thing.
Here I have marked up for the dog holes, also where the router plate will be and started routing out a 6 mm bed for it. Using the cordless trim router, that I make it for, but with the plunge base mounted for this operation, using a smple fence I move around, for straight edges.


Like this, next I moved the fence to other side, did that one and finally I used an edge fence to make the two other sides, quick and dirty.


Rounded the edges on the acrylic plate and it was a perfect fit.
Notice I made some dig in with the router in the middle, this could have been avoided with a larger base plate on the router, but as it will be cut out, it does not matter.


It's critical, that the plate is completely flush with the table.


I will use the smaller trim base on this, so I mark up it's size.


Drill through on the centre and mark up on the back side.


10 mm hole, inside the cut out.


So the jig saw can come in.
The reason I saw from the back side, is that the surface is flat there.


Getting closer.


And closer…


Marking up the corners.
As you can see I decided to make an extra plate, now I was at it, this one will just be in the box with my router, so I can make a quick and easy router table if needed or just used as a time table as it is.


Drilling and countersink in one step.


The plate can now be fixed with screws.


Using the trim routers base plate as I guide, the holes for attaching the router is marked up.
If you are watching this Jim, then please notice I use my favourite awl, thank you.


Drilling both at once here.


Counter sinking.


Plate mounted on the router.
I now also have a larger router base as a bonus.


Routing through the plate, with the largest bit, I will use as standard.
(I will not make any inserts for this version, put it could be done with a thinner acrylic).


Getting closer.


Drilling holes with 20 mm Forster bit, again almost through and the flip to drill from other side, to avoid tear out.
The table will be made in Workmate style, so it gets holes that match the once on the jaws, like this it can also be used as worktable without the rouer.


I made it at the same time as I made the jaws, so here they are.
It would have been nice, if they could be mounted like this…


The router also got a wee side fence in the disco acrylic.


Next up is the fence, here starting with the stop blocks.
Again some acrylics cut to square.


Rounding the edges with a 45° bit.


The stops will be used on a old fence, I found in the trash years back, but it could be any kind of fence, also just a piece of wood or thick plywood and clamps for the stop blocks.


The fence can also lay down, so I make two sets of holes in the stops.


To mount the pivot end of the fence, I use this thingy…


On the back side.


Fence goes over the bolt.


Just a 20 mm plastic or wood, with a hole in it, a bolt, washer and wing nut.


For the other end one of these clamps, I think it was from a jewellers bench pin.


Slightly modified to fit in the T track, but actually it was not needed.


It can now pivot from side to side and be locked down, with the clamp.


Close up.


Starting to look like a router table.


Let's test it out.


Using the stops to make a stopped cut.
Works perfectly fine.


The top.


The bottom, with router base mounted.
There will be no router lift, this will be manually.


Here you see the stopped routing on the base.


Like this you can put the small edge guide / fence on the router, while the plate is attaced.
To use it like this, for more freehand stability.


Or on the table, if that's all you need.


It will be plenty for a lot of on site jobs.


Back side, with router mounted.


Had to make a small cut out for the fence screw.


Finally it was time to make a starting pin.


I had a piece of aluminium bar, so just a threaded rod, a threded hole in the bar, washer and a wing nut.


Mounted on the table.


Here we are back in the allotment, the jaws are mounted on the table and four bench dogs are put in them.


Router top in place, ready to make panels.

Hope it can be to some inspiration, or perhaps open the eyes for other ways.

Best thoughts,

MaFe
 
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