Beginning a workbench - Input greatly appreciated

[cwarner]

Haha!  Obviously I was oblivious to the post date as well!  I dunno why it showed up high enough on the list that I posted in it.. oh well

[mike4244]

I am at the beginning of an adventure - I am going to build my own workbench. So far, I have 31 oak boards that used to be church pews, ripped and planed to either 3/4 or 1 1/4 inches. Beautiful lumber that I got for a pittance.

Boards are 3 1/2 inches wide.

I don't want to mess this up, so I respectfully ask you woodworking pro's for your input:

I a certainly not going to glue 31 boards at the same time. Also - of course boards are not 100% even - when put on top of each other, some stick out in the middle, some at the edges. I am not good with hand planes, this bench is supposed to change that. I am aware of flattening techniques using a router.



How would you proceed? I have about 32 inches total width. Should I glue 4 8 inch sections, flatten them individually, then glue the 4 sections? Or glue up one 5 inch section and then add piece by piece to that until the full width is reached?



Should I force the ones that stick out by clamping vertically while glueing? Should I straighten one edge before clamping?



I would really appreciate your input.



Thanks!



Dietrich



<img src=" =142898474&filters[recent]=1&sort=1&o=2"></img>]http://s723.photobucket.com/user/Dietric...gt;</img>


Joint all 4 sides. Rough cut for length. Bore for 7/16" for 5/16" all thread 6" from each end and about 18" oc. depending on the length of the bench. The perimeter pieces need a counter bore large enough for a ratchet wrench to take up the nuts. Usually about 1-1/8" forstner bit.
If you have a drill press use it for straight and plumb holes.
I use a home made press to align the boards. You can get the boards aligned with cauls and pipe clamps , Bessy etc. I would glue up 6/8 boards at a time using a slow setting glue like epoxy with a thickener. I would use West epoxy thickener that dries clear.. I do not use epoxy myself but am set up for multiple glue ups as I have built many benches for manufacturing  businesses. 
Make sure the all thread holes line up, I use smooth 5/16" rod inserted to make sure the holes are aligned.
The rods are replaced with all thread when the glue up is complete. 
Your sections will be between 5-1/2" and 7" wide depending on the boards thickness you use. About 5 or 6 sections to glue together. Do 2 sections at a time, trying to get the top surface as close to flush as possible.
Then glue 2 of these sections together, repeat  til your done. If you do not want to see the all threads then the perimeter pieces are added last with glue and dowels for mechanical fastening. The all threads may wind up long. adjust them so you only have to cut off from one side. A Dremel or other suitable tool makes quick work of this.
If you have high spots then take them down with a hand plane or your router jig set up. The swirl marks from the router bit should remove with hand sanding or maybe an orbital sander.
I used to have large equipment for this ,36" planer. 16" jointer etc. I actually have not used a router to level a top but I think it should work fine.
mike
 

[Hank Knight]

Mike4244 wins the "Oblivious" prize! ;~)