The Paul Sellers Plywood Workbench | Episode 3

[Music] we're about to finish off the legs we've got a little bit of trimming to do surface planing but I'm going to show you how I use my bandsaw to take care of some of the undulation because I think it's important first off I've got these beads of glue along here that have hardened up since I glued them up yesterday so I'm going in with my chisel flat on the surface just peel that down like this and then the next layer like that it just saves the hardness on your plane when you come to planing here now you could if you wanted to go ahead and play in this one surface but I'm not going to it's not really necessary so with this one I have to yet I'm going to run this through the bandsaw on this side because I still have the glue on this side but I'm going to use this straight edge on this side just to trim up the width and on this one this one I found that I'd left a couple of pieces that were slightly long that I forgot to trim down so I've got about maybe 1/32 of an inch to take that down so I'm going to do that on the bun so I'll show you how I do that hopefully that will all go well I've already got two of my legs planed up I use the the workmate to do that so that's done [Music] [Music] so now I've got to clean these up not complicated the outside faces on the main plywood faces don't need to be cleaned up so just position this in the workmate and don't forget to aisle the underside of your plane it makes such a huge difference to the plane ability so where do we start we'll start anywhere really and it really doesn't take too much this is the top of the leg so I probably don't need to get this is perfect but I will I'll take it all the way down until I get to it a clear level what my problem right here is I left one of them slightly low and the other three are high but I really have to take the high spots down only for appearances sake I know what you're saying Paul's got it the wrong way around but I don't like the way these are looking now because I may call this Paul's zebra bench or zebra beds it isn't the same as playing as planing planing that should be a verb shouldn't it planning plywood it's not the same as planning planing real wood but the work out is definitely good for me and I'm perfectly happy with that same on the other side she's a bit of a workout even for somebody as young as me and this fit is me okay [Music] you'll be surprised how little sanding this takes and of course you could use a a belt sander for this if you wanted to and that would take it down in a heartbeat but I think when I've done this I've got my heart pumping I'm getting my exercise my FX is going into this along [Music] down to the surface I want and now I've got my this is just a stanley plane with a curved iron that i've converted to a scrub plane so you can do that to yours just means i get a heavier removal of shavings so I'm taking the eros off developing a bit of a burr but watch this tell me if you don't like this this is the whole of my sanding for this this is 240 grit sandpaper and that's as good as I will get it off an orbital sander or a belt sander so I'm more than happy with that same on this one so I'm taking three strokes if you using a regular bench plane or the jet plane that will work fine sanding again amazing really if you think about it how much how little some paper we use to get the finish we want I doubt whether I will use twice as much some papers you see that I've got here just because I planed it with a hand plane there it is got these two faces to do and then one last speck on this now is I want to plane these corners are here at the bottom of the leg because if I don't they definitely will fracture as they do on solid wood or any wood so here 45 degrees when you drag it across the clunker concrete floor these will break if you don't do this and it will look nest nasty that will completely stop it no way could that happen now and that is my leg always prepared for fitting Tenon's so I've got that to do then I'll work on my leg frames dry run rehearsal that kind of thing there it is nice and flush finished blend now you start seeing it come together nice pockets nice mortise holes everything is great [Music] so here we go this is the the fitting part this is the part that I like the most I have chosen my pieces here I've chosen this for an outside face and this one for an outside face so I know how they're going this you may outside face there's no rhyme nor reason for what I chose except I did want a fairly fault free I mean yeah I want a fault free surface on the outside so this is how they are here are planed one edge this one he have not vrs off here just as I did on the legs taking the corners off and so I've got this he's going to go in here this is the first one and actually that one's all ready to go without me doing a single thing to it I'm very happy with that but not all plywood and not even on the same board they can vary in thickness just by a very small amount same board on this one everything the same this one doesn't just slide in although it does go with a little bit of pressure but that would be way too tight for a tenon to go in and so is that so what I've got to focus on is I've got to get my width right and that one looks like it's pretty close this one's close but where it really matters is on this outside edge I'm happy with that if you've got a gap don't worry about it because you simply make a wedge out of the plywood and you can drive that at the bottom edge and it will just disappear with the ply I'm not saying that's the goal I'm just saying sweat the big stuff okay so I've got this edge to plane here this is the underside of that rail so I technically would not really need to do it because everybody somebody would have to be lying on my back with their head that's only three inches wide to see it so it's not really something you need to do but I'm just gonna clean up this edge here just a little bit that's good enough not very soft here and this is the bottom one this has got through Tenon's these through Tenon's are rounded over and they protrude past the face of the legs half an inch I know that that's the case so there's a couple of things I've got to do with this neck see I've got to do my round always and I've got to fit that one tenon that I felt was too tight here what I want to do is put this tight up against the shoulder and just plain across the grain like this what that's going to do that's getting me within about three-quarters of that shoulder I could use a ball nose plane I could use a router plane to get that inside or I could just use this registration face now and just pare down this face so I should try that now before I go any further just a hair off didn't need a lot I hope it doesn't need any more it might do so this is going to go in here so already that's going now that just that little bit of a shaving off that surface that's nice that is about as perfect I'm not going to hammer this all the way in because I know it's going to go so now I've got to do my round overs are here I'm going to go back to my SuperDuper workstation here the one I'll be glad I had but the one I'll be glad I got rid of in a minute when I finish this bench okay we've got round all this to do it so if we drop this on here put a slight pencil line on we're going to start playing in this what I'm gonna do I've got all these planes and you I'm gonna use my scrub plane cuz it'll take a lot off so the line stops me going beyond that so I'm making this 45 degrees like that I've got this as tight as I can and it's still slipping there's nothing I can do about it drop my hung here like this and work up and keep altering the angle all the way onto the top keep it skewed like this there I am on the top I've got a perfect ball and I was nearly perfect same on this side moving on me again just keep working that round till you got your balls I'm gonna go with some 150 grit just to take some of the flats out so I'm sending this before I do the top of box and round over because it will keep the best of show okay leaves I'm gonna do with a chisel and see how well I do plywood is not like real wood drop your chisel on here start low down see it's breaking inside there so I've got to change my tactic here I'm going to drop this in here that's the trouble with plywood it doesn't operate the same so back off my iron on my smoothing plane I'm gonna try this yeah this is working so far yeah that's working fine then I just need a block of wood like this make a rasp or a file the follow this around looking nice I've got nice crisp edge go to some finer grit not as good as a rasp not as good as a file but it worked fine there's my nice crisp corner so I'm going to go with my playing the whole time I think got my 45 degrees now there's no doubt that a wrasse will work better or and a phial combined this is doing it this is getting me where I want to be so come up and follow that round like this this is a modern take on a craftsman-style usually apply without yes that's that one so I got to do the same at the other end [Music] that's the bottom rail and now fitting this I want to fit it but I still have to fit my top rail make sure that this goes in so it's the same procedure if it doesn't fit width wise we do exactly the same and I think that's going to go I'm going to check it on the outside face just to make sure you see there's a variation on there which means this is the outside face it means it's tighter on the outside so something has to have slipped so if I go on the inside like this it's hitting the top there if I come from this side it's over I think we'll see a discrepancy and I've got a gap this side of about a sixteenth of an inch which means that something shifted when I was in the assembly and so I've got to do something to compensate for that so this is going in this way so it means that what I've got is a cork shape here so that means that this piece which was fitting fine on this side and these are no longer fitting fine on this side it means I've got to taper this tenon by that one sixteenth of an inch which I can do perfectly well okay this goes here and I can make a mark right here so that's the distance I've got to cut I'm gonna try this this is just experimentation because this it's just how it goes when you're working like this it doesn't matter nobody's ever going to see this because it's the top one it's going to be behind the apron what does that matter of course it matters everything matters so it's not what you do it's how you do it that matters so here I'm taking this down [Music] there see that I think that is all I need to do to resolve that issue so this now fits in here just fine so I'm dead on now and I think there's probably enough in there for me to feel like this is going to go together what I'm going to do is go down corner to corner like that that's a little bit tight I think and then I go down on this one the thing is what you get is this increase in friction when you do this that's what you've got to be aware of as this goes in there's an increasing in friction so this is cross-grain planing whether that's enough I don't know now I don't need to do the shoulder in the corner particularly because the most of the friction is on this first two-thirds that it goes into the mortise hole so now I feel very confident much more confident look at that it's just a - it's just a hair really such a small amount so this one's done that one's great look at that one that and if anything that feels a bit loose this is just a variation in the thickness of the plywood shall we put this together and see what we are hot so here I've got the same issue as I had on the other one I'm too wide going into the hole this time and I'm really quite close on the outside but I'm going to take it off I don't want anything to hold this up when I come to the final assembly I'm going to take off just a hair check myself CFM parallel to the edge and then down this grain that's it one thing I do have to share which I forgot to and that is have I got clean shoulders in here or do I have glue in there and one of them I do that bottom rail did this one is fine does this fit it does that's going to go check the other side just to be sure that we've got the width we've got good width there so we know we're safe these are the faces that's going on I'm going to put a quick mark on here x marks the spot x marks the spot X X and X of those are in there so I know those are going to go together this one I'm gonna mark the inside with an A and this one with an A so we're good huh she's so scary what's the next thing I want to check these shoulders I just remembered in here some top well there's a little bit of glue in there one of them I could this one I can get with a knife just to make sure that internal corner is free and clear if it's a very tiny amount it's not going to hurt it will probably give but if it's a lot like see this one that's a quite a lot of glue on there too much so I've got these little beads of glue right on here and it's well set up so it's quite hard I've got someone the face here that could hinder it there we go that one's really not bad at all there this one is the same as that that's a bad one this can happen after you've glued out sometimes the glue will ooze out a few minutes after you've glued up and you may not have seen it so you should be conscious of that hands behind the chisel no cutting towards your fingers we're gonna try this see how we go okay planes out of the way chisel I don't need knife I don't think I need that really square I don't need okay some direct pressure for a little minute and I may switch between the hammer because I'm gonna hit the bench here like that and then I may hit the I'm going to use a clamp after that this one I only just fit someone I love this tenant coming through here down knocked down so I've hit a bottleneck but will it go what we do now is we go with a couple of clamps we'll do it combined with hammer blows because we've got to take this apart so as you're going if you feel like wow this is too tight and you've got to get it apart for gluing you have to be mindful of that but just by applying pressure with the clamp we can apply a little bit of extra physical pressure to deal with passive rebellion okay so what we do now is we apply pressure and then we we strike see it's so loose now just that little bit of extra pressure see this loose already it's just a combination of hammer blows this one's going easily here so I can get the whole of this this way but I want to go down parallel so be conscious of that I'll be able to get this apart after and if I can't then I'll just leave it now we have to do this we've got to get it together because we can't risk it on the glue up this is going quite easily now so I feel like I probably could just hammer blow this together now use the scientific approach thread so go here I get better leverage of course the shoulder line on this one's looking very nicely soft face don't use the hard face because you'll damage the plywood and it could be hard to get out hope you're enjoying watching this because I'm enjoying doing it knowing that you'll be doing it take up a little bit of distance just feel a bit tight so I'm a when I've done this and taking it apart I may consider shifting my thoughts and just taking another shaving so off this one here if I may do I'm not sure because the glue can work as a lubricant just as easily coming now so that last bit did go very nicely let's come up here Tenon's just produce it protruding past just a little bit not very much oh look at these shoulders mm-hmm that is so nice just about to run out of thread here look at that beautiful shoulders Tenon's protruding nicely now you want a clamp from both sides when you come to your final glue up because there'll be pressure on one side and up the other but I'm happy that I can now glue this together if I can get it about [Music] you

Channel: Paul Sellers

Views: 92,296

Rating: 4.9458103 out of 5

Keywords: hand tools, paul sellers, woodworking, DIY, workshop, joiner, carpenter, craftsman, crafts, furniture, joinery, workbench, plywood workbench, plywood

Id: 9H8vr0YZAbA

Length: 33min 56sec (2036 seconds)

Published: Fri Mar 22 2019