We want to make these pieces square, and of identical length. Square is a matter of making sure the saw blade is square and that the cutting guide is square. The trick to getting the pieces of the same length is to clamp them together and to cut them all at once. For the 4x4's, that means making a rough cut in each first, so we have four pieces, each 3-4" longer than we need, from which we'll get our four legs.
So drill the benchdog holes through the MDF layer. Begin by laying out their positions. You'll want these to be precise, so that the distances between the holes are consistent. The vises you are using will constrain your benchdog spacing. My front vise worked most naturally with two rows of holes four inches apart, my end vise with two pairs of rows, with four inches between the rows and eight inches between the pairs. Because of this, I decided on a 4" by 4" pattern.
Can't say enough about the team at Post Woodworking, Inc., from Karen in the office to the team that... put up this beauty starting at 7AM and were done before lunch, Kyle, Aaron and Billy. After what sounded like a late night at the shop the night prior, they were still on site bright and early as promised and still energized and ready to show their pride in their work. Couldn't be more happy with our 14' x 20' Cohasset. See More
Still, one of the best features about this woodworking bench has to be its vices. First off, the Sjobergs provides two vices both as sturdily constructed as the bench itself. The same hardware that fastens the bench works to ensure the vices are just as strong. The next main benefit on the vices in the inclusion of multiple positions – four in total – for the vices to go. This allows you to mix and match to suit your needs and allows the table to be used just as easily by right-handed and left-handed users.
Flip the base upright, put the MDF on top of it, then use a straightedge to draw two straight lines joining the outside edges of the legs and extending the width of the MDF. I used the countertop as the straightedge. We cut it with our cutting guide, which is based on the factory edge of a sheet of 1/4" plywood, so it should be straight enough. Use a carpenter's square to transfer these lines onto the ends of the MDF.
Before joining the top to the base, loosen the bolts and screws on the lower stretchers to create a little play in the leg posts. Align the top notches with the leg posts and tap the top into place with a hammer and piece of scrap wood, working evenly around the table until all leg posts are level with the tabletop. Tighten the lower stretchers and you’re done. A hefty thanks to Doug Merrill for this weighty idea.
Synopsis: No room in the garage? Basement not an option? Consider what Ken St. Onge did when he needed shop space: He bought a prefabricated shed and converted it into his full-time woodshop. Because a pre-built shed doesn’t need a cement foundation and is built in a factory, it’s much less expensive than building an addition or stand-alone shop on your property. It can have taller ceilings than a garage and bigger doors than a basement, both big pluses for a woodworker. You can put a shed just about anywhere, too. Here’s a soup to nuts look at Ken’s experience, so you can gauge whether a shop in a shed is right for you.