In the shortly established tradition of me, I present another task list for yet another household project.

This latest windmill is actually a gorgeous and functional workbench that replaces the built-in, epoxy-spattered, crumbling surface that came with the house.

Enjoy.

Build Cabinet

1. Buy shim stock for jointer
2. Buy more poplar for test cuts on band saw
3. Empty dust collector
4. Inventory and organize tools and materials
5. Arrange garage to cut plywood and assemble cabinet
6. Clean and tune table saw (Wood #161p18, #167p30)
7. Cut all cabinet parts (AC fir plywood, parts D & E)
8. Assemble 3 ea. cabinet boxes on table saw
9. Join cabinet boxes together, side by side
10. Cut birch plywood ends (H) and attach to box
11. Measure top of cabinet for top (C), cut, attach
12. Measure back for back (B), cut, attach
13. Measure front and sides of cabinet for face frames (leave some extra space to allow for routing flush with cabinet)
14. Cut/joint/plane birch for face frames
15. Assemble side frames with pocket screws
16. Finish plywood on sides not covered by frames
17. Glue, tack w/ brad nailer, clamp side face frames
18. Route side frames flush with front of cabinet
19. Assemble front face frame with pocket screws
20. Glue, tack with brad nailer, clamp front face frames with a lip to register the base
21. Route front face frame flush with sides of cabinet
22. Plan storage in cabinet for location of pull-out shelves
23. Build T-square jig for locating drawer slides
24. Draw center lines for shelves and drawers
25. Install drawer slides
26. Finish top of cabinet

Build Top

27. Install ½” blade in band saw
28. Lube band saw blade with lube stick
29. Tune up band saw to cut top blanks
30. Cut top blanks (try to allow for vise jaws [2 ea 5½”x36”, 1 ea 5½”x18”, 1 ea 3¾”x18”, and top supports [2 ea 5”x30”, at least])
31. Tune up jointer
32. Cut/joint/plane top blanks as needed
33. Glue short top blanks end-to-end (use pipe clamp with coupling)
34. Glue top blanks into three 12” sections
35. Scrape off glue squeeze-out
36. Change planer blades
37. Work up an in-feed/out-feed solution for planer (maybe MDF table on top of planer?)
38. Plane top sections
39. Joint edges of top sections as needed
40. Glue top sections one joint at a time
41. Scrape off glue squeeze-out
42. Trim ends of table with circular saw

Install Vises

43. Measure for clearance between top of cabinet and top for vises
44. Confirm vise jaw dimensions using worksheet in vise instructions p7
45. Consider shifting right top support to clear end vise carriage and lead screw (drill holes to accommodate lead screw and guide rods)
46. Cut/joint/plane top supports (make ends interesting or pretty)
47. Finish top supports
48. Cut/finish/install vise handles with 1 1/8”x12” dowel and toy car wheels
49. Drill bench dog holes according to pattern in Wood #166p39, use technique in Fine Woodworking #182p90
50. Lay out holes with masking tape (check for clearance with vise carriages and jaws)
51. Make drilling jig (Wood #166p14)
52. Drill 5/8” pilot holes
53. Attach ¼” Masonite auxiliary fence to plunge router
54. Route holes from top with ¾” bit
55. Flip top and finish holes with ½” bearing-guided bit
56. Route holes in front edge with ¾” bit
57. Chamfer all holes with 1/16” round-over bit
58. Cut aluminum angle to length for top of cabinet and top
59. Mill holes and expansion slots in angle (cut only the outside hole and slot in the top right angle to account for end vise)
60. Attach angles top supports (make sure that top angles face towards the ends of the bench)
61. Cut/joint/plane vise jaws (2ea 5½”x 18”, 2ea 5½”x 36”)
62. Drill ¾”x1¾” bench dog holes in front jaw of end vise (top and left edge) and front jaw of front vise (top edge) to match spacing of bench dog holes in top
63. Stick jaws together with double-sided tape (keep ends and bottom edge of front-vise jaws flush, and all edges of end vise flush)
64. Draw centerline and carriage base line on each front jaw
65. Remove p10 of vise instructions (large vise template), cut out alignment windows
66. Use template to transfer guide rod and lead screw centers to jaws with awl
67. Tune up drill press and auxiliary table on press
68. Use 1¼” Forstner bit to drill lead screw holes through jaws
69. Use 1” Forstner bit to drill guide rod holes through front jaws and just enough to mark centers on rear jaws
70. Separate jaws
71. Route 1/8” round-over on outside edges and ends of both front jaws
72. When to route 1/8” round-over on rear jaws?
73. Use 2-3/8’ Forstner bit to bore 9/16”-deep counterbores in rear jaws centered in guide rod marks for guide rod support collets
74. Use 1” Forstner bit to finish drilling guide rod holes through rear jaws
75. Use 11/16” Forstner bit to drill 3ea. ¼”-deep counterbores in bottom edge of front vise rear jaw
76. Use 11/16” Forstner bit to drill one counterbore in left of rear jaw of end vise and 4ea 1¼” slots for expansion washers
77. Use ¼” brad-point bit to drill holes centered in both rear-jaw counterbores and slots
78. Clean up slots and holes with chisel
79. Clamp front-vise rear jaw to bottom surface of top, flush with front end and left end of top
80. Clamp end-vise rear jaw to right end of top, flush with top surface and front and rear edges
81. Drill 3/16” pilot holes in top for all rear jaw mounting screws
82. Attach jaws to top with ¼” lag screws and flat/expansion washers
83. Lay top supports on cabinet
84. Test fit top to cabinet, confirm and mark location of right support to clear end-vise carriage and lead screw
85. Separate vise fronts from carriages (page 4 of vise instructions)
86. Cut carriage 2ea. spacers to size and 4ea. supports to prop up front of vise from ¾” plywood
87. Lay carriage spacer behind rear jaws (center the end-vise carriage)
88. Slide guide roods into carriages from rear until lead screws contact back of rear jaws
89. Prop up vise fronts with plywood bit
90. Slide support collets onto guide rods (countersunk side facing out with flats of collets towards top surface of top)
91. Center collets in counterbores
92. Clamp carriages in place
93. Spot holes for collets with 15/64” drill bit through collet holes
94. Drill pilot holes in jaws for collets (7/32” x 1¼”)
95. Attach collets to jaws with supplied #14 flathead screws
96. Remove vise fronts
97. Drill 21/64” shank holes through carriage spacers and pilot holes (7/32” x 1½”) in top for three rear carriage holes
98. Attach carriages to top with ¼”x2½” lag screws and ¼” flat washers through rear holes
99. Remove rear jaws
100. Drill shank holes and pilot holes in top for two front carriage holes
101. Finish attaching carriages with lag screws in front holes
102. Reinsert vise fronts from rear of carriages
103. Slide rear jaws on guide rods and refasten jaws
104. Remove vise fronts
105. Slide front jaws onto guide rods
106. Insert rods into collets in rear jaws from the front
107. Draw jaws together with lead screw
108. Align jaws, tapping with mallet
109. Drill pilot holes in front jaws for collets (7/32” x 1¼”, consider 7/16” thickness of jaw when setting drill stop)
110. Attach jaws to vise fronts with supplied #14 screws
111. Open end vise until guide rods don’t protrude from the back of the carriage
112. Install right top support to bottom surface of top behind end-vise carriage
113. Make 2ea 6-layer pads of masking tape and stick to top support behind guide rods
114. Use pencil to coat end of guide rods with graphite
115. Mark guide rod locations on top support by closing vise
116. Cut out guide rod holes in previous template
117. Mark centers of guide rod and lead screw holes
118. Remove right top support
119. Use 1” Forstner bit to drill guide rod holes
120. Use 1¼” Forstner bit to drill lead screw hole
121. Use ¾” bit to bore through bench dog holes blocked by vise carriage spacers, if any
122. Remove end-vise front w/ jaw still attached
123. Remove end-vise rear jaw

Build Cabinet Base

124. Cut/joint/plane 2x6s into straight 2x4s
125. Cut 2x4s to length (flush with bottom of cabinet)
126. Assemble base frame with screws
127. Cut base top (A) to size and attach to base frame
128. Attach casters to base with 5/16”x1¼” carriage bolts, torque washers, flat washers, split lock washers
129. Relieve bottom of cabinet at carriage bolt heads to allow base and cabinet to mate flush
130. Attach base to cabinet (flush against lip in front face frame)
131. Fill in front face frame overhang with scrap lumber to provide solid base for molding
132. Cut/joint/plane base molding
133. Route cute profile on top of base molding
134. Miter ends of molding
135. Attach molding to base with glue and brad nails

Attach Top

136. Install top supports to table
137. Lay top on supports and align top as installed
138. Mark location of top right angle on top (behind end vise)
139. Mark location of additional slots in top right angle for attachment to right top support
140. Mark location of holes in left top angle
141. Remove and flip top
142. Mill remaining slots in top right angle
143. Drill 3/16”x1¼” pilot holes in bottom surface of top for lag screws
144. Install right top angle with 5/16”x1” lag screws and flat washers
145. Lay top on supports and align
146. Attach top with 5/16”x1” lag screws and flat washers in left angle
147. Attach top right angle to right support with screws
148. Slide end-vise rear jaw on guide rods
149. Slide guide rods into end-vise carriage
150. Reinstall rear jaw

Build/Install Doors, Drawers, and Shelves

151. Cut three door blanks from birch plywood
152. Cut ½”x¾” birch for edging all door blanks
153. Glue edging to door blanks
154. Cut 3/8”x3/8” rabbet in edging (use table saw or router table?)
155. Crosscut three drawer fronts from one door blank
156. Cut birch plywood for shelf bottoms, drawer bottoms, drawer sides, and drawer fronts and backs
157. Cut ¾” rabbet drawer fronts and backs for sides
158. Assemble drawers with glue and screws
159. Cut/joint/plane shelf trim birch ½” thick x 1½” wide
160. Cut shelf trim birch to length
161. Route 3/8” round-over on shelf sides
162. Route stopped 3/8” round-over on shelf fronts and backs to match round-over on sides
163. Assemble shelves with glue and screws
164. Finish top, cabinet, drawers, shelves and doors
165. Mount drawers and shelves
166. Attach handles to drawer fronts
167. Make shims to install drawer fronts
168. Mount drawer fronts using shims to align
169. Attach doors
170. Attach handles to doors

Pakeha

Columns by Pakeha