In the Birth Canal

This morning I processed the stock for 18 more sawbenches that we’ll build during the “All About Hand Tools” class I’m teaching this coming week at the Marc Adams School of Woodworking.

I feel a bit like a midwife on these days. I’ve helped build about 60 of these benches during the last few years, but I rarely get to see my babies after they leave the class.

But helping people cut more than 240 angled birdsmouth joints on the legs and 480 half-lap joints always inspires me to find ways to make this design more material-efficient, lightweight and strong.

The first version of this sawbench used twice as much material and took twice as long to construct. The lessons buried in that design (drawboring and wedging tenons) were the driving factors in its beefy-osity. Today I’ve got this design pared down to where I can build a sawbench in about three hours using hand joinery alone.

In addition to making these quick to build, I’ve also put the suckers on a diet. To build 20 sawbenches, I need only seven 2 x 12 x 10’s and five 2 x 8 x 12’s. And the leftover waste from ripping and crosscutting all that stock won’t fill an office wastebasket.