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255654 David Nighswander <wishingstarfarm663@m...> 2015‑08‑03 Re: horror story . . . was it the crappy wood?!
I intended to make a workbench. 
After 40 years of not having a proper woodworking bench I thought it was time. 
Thinking that I was being clever I set myself a task with a deadline. I told
LOML that I was going to make a bench for my sons birthday gift.
With all the trepidation involved in the beginning planning of any project I
went with the Paul Sellers method. It closely matched my fathers methods in that
it involved 2x4’s and glue. Dad always threw in lag bolts on any project and his
favorite glue was PL400 in the caulking tube. The large caulking tube.
I cheated with a tailed apprentice in some steps. Removing 1/4” of radius from
the edges of the fifteen 6’ long 2x4 seemed like a job for the big blue planer
that had sat in the corner of the garage since the move. I glued up two 12” wide
planks of 2x4’s face to face.
For a spreader I zigzagged Titebond III glue over the face of one board and
rubbed the other across it. Seeing that I have a plethora of clamping devices I
gripped the planks mightily and left them to sit overnight while I went off to
earn the money for more glue.
After rough planing one face with my Stanley #5 I bashed them through the
planer. Because I wasn’t sure exactly how long the bench needed to be I had left
the 2x4’s at their original 96” length. A fair amount of fast footwork was
involved in making multiple passes but it finally was done.
When I got back to the task of assembling the planks I found that during the 2
days of idleness in the garage the planks had twisted. Only about 1/4” but
enough that it would be obvious. Using mechanical means and several cauls I was
able to bring a 6’ section of the planks into alignment. Having settled on a 6’
long bench the rest was rather anticlimactic.
The bench was well received and arrived at its new home in the originally
designed number of pieces. It needed to go down a set of stairs with a dogleg so
it was designed to be disassembled.
It has been in use the most of a year and seems happy to be of service. No
further warping or twisting has shown up. The one half that is Douglas Fir is
coexisting nicely with the white pine half, that was all that was available
during the second trip to the Borg.
Why did it work? Don’t know. Don't care. I used the same method on a similar
bench for my shop that has been most satisfactory.
If you are interested you can see the bench in various stages here. 
https://www.youtube.com/wa
tch?v=EZ2yHekr00A
The second bench top was hand flattened after the final glue up. No matter how
many clamps I used I couldn't pull it into alignment.
The second bench top shrank to be about a 1/2" narrower after the final gluing
and before the base was attached.

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