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After years of [ab]use, my trusty saw bench is ready to retire. However, before I can retire the old I must make a new. So that was the project this weekend.

The saw bench is an absolute must have appliance for the hand tool shop. A pair is even better, especially if you process long stock in your shop with hand saws. In addition to supporting stock at a comfortable and convenient height for crosscutting and ripping, the saw bench serves a myriad of other uses in the shop. I use mine to sit on when boring with a brace, as a side table to hold tools and project parts when working at the shave horse, as support for case pieces when I'm planing their dovetails flush, as a bench to sit at when drawing at my workbench, as a step to reach the boards on the top tier of my lumber rack, as a place to sit and take a coffee break and as a second workbench for my kids when they are in the shop "working" with me.

I don't like to over complicate tools and appliances for the shop as I consider them disposable. They get used hard and take a lot of abuse so I don't use expensive lumber or complicated joinery. I want something that will be sturdy and will last but won't cost a lot and will be quick and easy to build. The style of saw bench pictured fits that bill nicely and can be built with cheap lumber and traditional joinery. This makes it very sturdy since it doesn't rely on the strength of mechanical fasteners like nails or screws, but it also stays very lightweight and easy to move around or store out of the way when not needed. It's relatively small at about 30" long by about 12" wide and at about 18" tall (approximately knee height for me) it is the perfect height for processing lumber with hand saws. No shop should be without one of these, or preferably a pair.

Check out the Articles page to see how it was built.


 


Comments

simonm

Wed, 06 May 2009 04:27:40

Thanks for that Bob.
You've certainly got the knack of giving good tutorial.
A lot of stuff you read on the w3 seems a bit intimidating and unattainable.

 

Wed, 06 May 2009 04:53:37

Another project I've been meaning to build! There have been many times I wish I had a pair of sawbenches and can see where they would come in handy in several ways.

I have seen other sawbenches with a V-cut in one end. Is there a reason you didn't do that? Are they necessary?

 

Wed, 06 May 2009 05:39:16

Thanks Simon! I think a lot of writing & writers tend to over complicate things. I try to take the approach of not worrying too much about getting it perfect and instead just getting out in the shop and building it. You figure things out as you go. There's really no way to plan for everything ahead of time. I really think anyone can do this.

Kari,
I've been using a sawbench without the "V" notch for years and really have never wished I had it. I've heard it referred to as a ripping notch but I think the folks who call it that have never ripped lumber by hand; at least not often and/or effeciently. Theoretically, the "V" is supposed to support stock as you rip with a hand saw. However, I can't see it really doing much in actual use. At least not the way I work.

When I rip stock, the board is typically extended off the front of the bench much further than the depth of the notch would be. If I were to only saw to the depth of the notch I'd be moving the stock every two strokes. My rip saw is pretty aggressive and in 4/4 pine I can easily rip 1-2" per stroke on a good day with a sharp saw once I get into the rhythm. I don't want to stop constantly to move the stock so I typically have 6-12" of the board overhanging the end of the saw bench while I'm ripping. The "V" notch would do nothing to help support the cut in these cases since the length of the rip is much longer than the depth of the notch.

The other way I rip, when the stock is wide, is to hang the waste over the side of the bench and rip continuously along side the bench. This way, I don't have to stop that often to move the stock. Again, the "V" notch wouldn't be much help with this. Finally, for long stock, I rip with the stock placed across 2 saw benches (actually one saw bench and the back end of my shave horse) turned sideways so again, the "V" notch wouldn't be of much use.

I can see the notch being useful for supporting short stock for fretsaw work. But I don't do this kind of work on the saw bench. I have a separate board with a "V" notch cut in it that I clamp to my carving jack for fretsaw work to get the piece up on the bench where it's easier to see and do precision work.

 



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