Making a workbench frame
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Making a workbench frame

October 15, 2019


In this video I make a sturdy workbench frame. The first thing to do is to check that our circular saw guide is still at 90 degrees. If needed we remove one screw and then we adjust the guide again. We measure the length of the legs. And with the circular saw and the jig we cut the legs. If our disk is not big enough we cut, and then we turn the leg, and we finish the cut. If both cuts are not flush we can use a planer to smooth it. We make sure all four legs are the same length. We adjust the depth of cut to be bigger than half the thick of our board. And we adjust the guide to cut the pieces to the wide we want. We cut our boards to make the rails. Because the disc won´t cut all the thick of the board, we can cut it on the table. We cut on one side, we turn the board and then we cut the other half. We mark half the thick of the head of one rail, and we adjust the depth of cut of our circular saw to that mark. We make some cuts in the head of two pieces with the same thickness of the rails, to see if the depth of cut is ok. It looks like it cuts too much, so I needed to make some adjustments. After some adjustments finally it cuts to the right depth. We mark the position of the dados and the rabbets we need to cut in the legs to fit in the rails. That line is inside the dado we want to cut. That line is outside the dado. And that other line is outside the rabbet. We have to make two identical dados in two faces of the legs, one at 90º with the other. All four legs are the same. We put the edge of our saw guide by the line, but not on the line, and we cut. Now we need to leave the teeth width of our saw disk between the line and the edge of the guide. Or we can cut it from the other side, with the guide on the line. We make sure that the dados and rabbets are the same wide of the frame rails. When we use the jig we don´t cut to the wished depth, so we need to go over it without the jig. And we make some parallel cuts between them. We use a chisel and a hammer to remove the slices of wood. We clean the bottom by hand, with a chisel and a file. We use the same method to cut that other dado, which is at 90º with the first one. Notice that I leave the width of the disk teeth between the line and the edge of the guide. Now we put the jig right on the line (remember that this line is not inside the rabbet) and we clean the rabbet. We cut the short rails to the wished length. If we put the rails on the table we can cut easily on them. We measure the long rails for the workbench frame and we cut them. We write a C on one end of each rail, and a L on the other end. In the L side we cut a rabbet as long as the width of the legs. In the C side the rabbet is as long as the width of the leg minus the depth of the rabbets. Notice that the lines are out of the rabbets. We use the legs to mark the width of the rabbets in the rails. We put the guide on the line and we cut the rabbet. The same we did with the legs. It is a good idea to check that the rails and the legs fit. We may need to make some adjustment. On the floor we put together the long rails and the legs. The top face of the rails must be as straight as possible. We put the C rabbet of one of the rails on one leg, and we put the C rabbet of the other rail on the other leg. We put the rails flush with the top of the legs, and we use a square to make sure that the legs and the rails are at a 90º angle. We drill guide holes and we put a couple of screws. We can widen the rabbets with our circular saw if needed. We do the same with the other side of the table. If we don´t do exactly the same the short rails won´t fit. If the rabbets in the head of the rails are too long, we can cut them, or we can use a file to adjust them. Now we clamp the other rail, but not too tight. If they don´t fit inside the dados, we can use a planer to narrow the rails. We use the square to adjust the rails and we tighten the clamps. We drill two guide holes and we put a couple of screws. We put some reinforcements inside each corner. We leave the same distance to each side and we mark the miter line. The line must be at 45º. Before putting the corner reinforcements, we will glue the legs and the rails together. I will apply polyurethane glue with a small brush. It expands and fills the gaps. Some polyurethane pours out of the joint, but it is easy to cut when it is dry. When we put the rails back in the legs, we must make sure that the screws go in their guide holes in the legs. The pieces we will put inside the corners are small. If we have a miter saw it is easy to cut them. If we don´t have a miter saw we can use a couple of screws, a piece of board and a couple of clamps to hold the piece. And we cut it with a circular saw. We tilt our saw disk to a 45 degrees angle. It is better to make sure that we have exactly a 45º angle. We mark the lines where we want to cut. We wear the safety equipment before we plug in the saw. We must make sure that we will not cut on the clamps. We cut freehand. This will be a workbench for my shop, so I don´t mind if it is not absolutely perfect. If the disc doesn´t cut all the thick, we can finish it with a hand saw. We remove the screws and turn the work piece. Or we can cut from the other side. If needed we can use a file to make them fit in place. We clamp the pieces, we drill two guide holes to each side… and we screw them. We remove the clamp, and we screw the piece to the leg, too. We put in place all the pieces to reinforce the frame corners, and there is it, a sturdy workbench frame. Thanks for watching!

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  1. Sergio: disculpa que se un ignorante. No se ni entiendo el ingles. Pero, por lo que vi, parece ser sencillo. No importa no volveré a dar ninguna opinión.

  2. I signed up your other channel even though I don`t understand Spanish. But your videos make all clear. Thanks a lot for all your work!

    I am German. My English is really poor and sometimes I have problems to understand people e.g. from India, China or even Scotland. (This is no critics at all!)
    I had really no problems to understand your words and now I will sign up this channel too.

  3. Whatever the language does not matter, the important thing is what it means to achieve their objectives. And in this case everything else can be understood. I Am Indonesian. and Google a lot of help in translating any language .. Ahahahahha …. Glad to see all your videos Sergio .. (Y)

  4. Sir. I apologise for commenting so late, I only came across your video today. Thank you for your channel and simplicity and use of minimum amount of tools.

  5. Really enjoyed this video mate! I like people like you who think outside of the box. Your circular saw guide is very clever, well done. I am going to copy that idea for my own circular saw – I am having trouble getting consistent cuts every-time. This little Jig should sort that out. I will upload the video on my channel you can give me your feedback as to if it's any good 😉

  6. I like your work Sir !! although I find your accent little funny but I loved it because it feels so friendly:) Your work is so easy to understand and easy to follow !!Thank you Sir !!

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