Since I missed my Christmas deadline I lost a lot of my urgency and to get back some enthusiasm for the project and to perfect my technique I decided that I needed do something with laminate so I could prepare for the counters. I've done it before but it was a long time ago in my studio in SoHo and I was Festooless back then so I wanted to take stock so to speak.
I was also getting very frustrated at trying to build and work in the garage without a bench. My tools end up on any flat surface and some not so flat and it's a testament to Festool that they've survived a few good drops without a scratch but it's a pain to work without one so I figured a bench would be a quick and easy project. So that's what I worked on this week between drywall repairs. It wasn't quick.
Quelle surprise!
Any time I'm not working in the house I'm sketching projects for the house. I started to keep a Moleskine journal for my project drawings as I found it helpful to keep them in one place but the journal has actually gotten me to start sketching more. It's a happy circle.
So my initial plan was to build the benches to float over the Sysports but to also create some hidden storage behind them in the form of a 200mm deep space that I'd use for awkward sized jigs, rails, squares and such. The Sysport would back into them and cover them when not in use but could easily be moved to get things as needed.
Since I'm not an engineer I build based on hunches, experience and testing. Testing is something I learned from my assisting days with
Gregory Heisler, the photographer with whom I apprenticed. We tested everything you could imagine and that's one of the reasons he was so good. So as I built my bench I would clamp it and test for flex on the cantilevered portion. If it flexed I changed the design by adding more bracing and then making cutouts to lighten it and gain access to the eventual slides.
This is looking at it the right way up but the far long edge will go against the wall. I added all the bracing so I could screw through the lower cabinet into this one for the connection. I'm using 18mm for everything but the bottom which is 1/2". The exposed ply is baltic birch but the internal bracing is just the cabinet grade 3/4" I had lying around.
This is test fitting the top which is 18mm baltic birch with a boat load of dominos. I decided to change the settings on domino to the narrow mortise which fits the domino tenon exactly. It means your measurements need to be spot on but the fit up is
tight! It's essentially a torsion box and I'm happy as it's all tight, exact and strong.
Next up was to cut the laminate oversize for the tops and then glue a scrap of laminate to a scrap of ply and test the router and dado bit combination to make sure I could cut the channel in the top without chipping the laminate top and get the right depth for the T-track.
And the 3/4" bit set to 10mm was a perfect fit keeping the T-track set just .3mm below the surface of the laminate.
My plan is to embed either 3 or 4 T-tracks short wise on the table to use for clamping and the miter saw fence. When the saw is not in use the fence can be slid back to act as a backsplash to the bench. That's the plan at least. I had to quit early today to do some last minute shopping (the only kind I do really) and so I left it all ready to finish but I'm pretty confident that the bench is going to turn out well and that bodes well for the kitchen.
Merry Christmas all!
Gregor