Woodworking Work Bench

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" The first thing every woodworker needs is a work bench. Even before any tool is purchased you need a work bench. There are a million designs and every woodworker has a different work bench, even if they are based on the same plan or design. A number of our members have asked be for more details on my work bench and so that is what this video is to do, review one option in work bench design.

Wood Thickness Differences / Rough to Planed

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On a trip to your local home depot or woodworking supplier you might notice the different wood sizes on display, and be scratching your head wondering what it all means. There are a couple important things to remember when purchasing stock.

2x4 vs 1 ½”x3 ½”

The first is that 1 inch doesn’t always mean “1 inch”, so while the label might read 2x4 it actually translates to 1 ½” x 3 ½”, because of dryness and milling methods. Wood tends to shrink when it’s dried and lumber mills make adjustments accordingly. That said, the length of a piece is generally not affected so a piece “measuring” 8’ is usually very close to 96 inches.

All About Radial Arm Saws

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Radial Arm Saws tend to be one of the most under-appreciated of woodworking machines which is disheartening, considering how versatile they are in the range of operations and tasks they are able to perform.

Why opt for a radial arm saw

While they may be on the pricier end of the scale, and they do tend to be both heavy and not typically fit to carry around easily. As a result, they are used mostly in professional shops where portability isn’t a priority.

That said, the variety of operations that a radial arm saw can perform from ripping to cutting bevels or miters, dadoes and rabbets, forming mouldings and in some instances, serving as router guides; is nothing short of amazing. However, like any tool there are trade-offs which come hand in hand with its versatility: difficulty in setting up cuts (as opposed to a compound miter) taking a longer time to rip stock (table saws rip faster). That said, the radial-arm saw is able to perform both these tasks, albeit a little slower than other tools, but again, it is a small price to pay.

Plywood Grading - Types of plywood

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When buying plywood from your local Home Depot, Rona, Lowes or other wood supplier, you might have noticed that all the plywood is "graded". The most common plywood grading scheme is from A to D, with A being the highest quality with zero blemishes and great sanding, and D being the worst with the greatest number of blemishes (allowed).

Grading also typically comes in pairs where each grade addresses a different side or “face” of the stock piece, ie one letter will address the quality issues of the front face and the second, the side opposite to the face. So for instance, an A-C plywood sheet would be highly finished on the front face with a relatively poorer finish on the back. Similarly, construction grade C-D (referred to as CDX) plywood, is great for structural use but not for projects requiring a high quality finish.

Bonding Types

Along with the plywood grading system, plywood comes in different bonding where each type is differentiated by the glue used to bind the layers (aka plies) of plywood. We’ll cover each in turn.

Interior Plywood
This type is made for interior use only, from hardwood and softwood species and is generally used in places where exposure to moisture is minimal, e.g. furniture, wall sheathing, cabinetry, etc. Interior plywood is available in most grades and comes in a variety of hardwood species like birch, oak and cherry.

Exterior Plywood
By far, much more sturdier and moisture-resistant than interior plywood, this type can be used outdoors and is easily available from local suppliers. Like its interior counterpart, it also comes in various grades—A-C, B-C and CDX are widely available—and hardwood species.

Marine Plywood
If you’re really looking for highly moisture-resistant plywood, look no further than Marine Plywood, which is both manufactured in top quality and uses the highest adhesives. And though commonly graded A-A for two highly placed faces, hardwood choices for exterior use (where the type would be most useful) are limited.

Structural Plywood
If you’re looking for beauty over brawn, this type is ideal although it is rarely found in a grade higher than C-D and is atypically used in construction sites (as concrete forms). Special resins are used to adhere the layers together and they are designed in such a way that the plies are less likely to separate.

Plywood Sizing
Just like hardwood and softwood sizes, plywood sizes can be just as confusing if not more. Although sheets are usually sold as 4’ wide, they may sometimes be found in 2’ and 5’ widths. Similarly, just as a typical plywood sheet’s length is 8’ they can also be found in 4’ and 12’ sizes as well as metric sizes. The variety can easily confuse the best of us.

And that’s just the beginning; the variation of sizes above will be a walk in the park compared to the thickness dimensions. Common sizes on the US market are ¼”, ½” and ¾”. That said, a ¼” plywood sheet is really 7/32”; ½” a 15/32” and ¾”, a 23/32”.

And though the 1/32” doesn’t seem like much, it can make all the difference when working with plywood. Consider this: a wood craftsman is constructing a bookshelf where a ¾” shelf is inserted into a dado cut into the shelf standards; the 1/32” gap will not only be noticeable, the dado will feel sloppy and unprofessionally handled. To counteract such a situation, the dado will need to be cut at 23/32”, ensuring a snug fit.