Help!

[jseklund]

OK guys, I need some help here.

I was going to build a workbench as my first project, but my girlfriend asked me if I could try to build her a little bench to put some "dolls" (for lack of a better term) on. I thought it would be great. I could buy some cheap pine at HD off the culled rack for about $0.50/board and throw something together, and do some learning on how to use the tools, make cuts, make joints, etc. before I spent $$ on some nicer wood. Boy am I glad that I did. I just spent all this money on tools and don't have much left over for wood. I think I would have spent $300 on wood and destroyed it all if I had tried to build a nice bench. Big dreams- I was way ahead of myself.

Anyway, I'm going along doing fine, until I get to the back legs. Essentially, the back two legs have to be identical or at least close so that the bench will sit square when I'm done. My problem is that I got a couple of plans off the internet for full-sized benches, did up a couple of quick drawings, scaled everything down, and started cutting. The plans called for a 7 degree turn in the rear legs as they meet the seat (approx.). The front legs are pretty much just square blocks. The 7 degree turn is throwing me for a loop. The plans I got said use a band saw (which I don't have!) so I have to use my jig saw. I've tried:

1. Rough cutting with the jig saw and sanding into shape. This makes for boards that are not square at all. Wavy lines, thicker on one side than the other, etc.

2. Rough cutting with a jigsaw and then using a flush cut bit on the router to get it square.

3. Cutting with the jig saw, and then jointing the front on the jointer.

I don't know what to do. So I guess my questions are:

1. Does anyone have any suggestions on how to cut flush with a jigsaw (or any good articles I should read)?

2. Does anyone have any suggestions on how to use a flush cut router bit on a thinner surface? (or any articles I should read).

3. How would you achieve the goal of having a squared up block of wood with a 7 degree turn in it?

The jointer method ALMOST solved the problem. However, I can't joint the backside, because it bends up and away from the blades. It's difficult to square up the back in particular in other words.

Maybe I should have put this in the "getting started" category. Any help here is greatly appreciated. I think I've run out of four letter words to use while I'm trying to do this. However, I have learned a lot about what NOT to do. Glad I started with $0.50 pine boards.

Thanks in advance for the help!

[Bruce Cohen]

Stuff like this happened to me all the time when I first started out and still happens.

When I run into something thats beyond abilities, and the alternative is to either screw it up or give up in disgust, I try to modify the plans to "fit my skill level".

I find this works out much better for both the project's appearence and your level iof indigestion, not to mention hours of stnading in the shop and cursing at yourself.

I usually allways approach a project with my abilities in mind and then find a way to cheat to make it look like I know what I'm doing.

Hang in there, it gets to be even more "fun" and more expensive, like screwing up 10 board feet of Macassar Ebony @ $55.00 a bf.

Bruce

[lrogers]

Since both back legs will be the same, try this. On the first piece, clamp a straight edge to your stock for the jig saw to guide against. This should give you a nice straight cut with no waves. Cut the first piece very carefully and finish sand the edges. Then take a rough cut blank for the second leg and use carpet tape to stick it to the first piece. Then use a piloted (guide bearing on top)pattern bit in your router (bearing riding on the finished piece) to finish off your second leg. This way, both legs will be identical and the second leg will require very little in the way of edge sanding. Just don't go too fast with the router. I've used this method many times with great success.
I just came in the shop a little while ago and I'm preparing parts now for just this way of doing it. I cut the first blank carefully, this will be the master. The other three, I left between 1/8-3/16" of inch of excess material.

Hope this helps!

[LCHIEN]

yeah, like larry says.

[jackellis]

"I think I would have spent $300 on wood and destroyed it all if I had tried to build a nice bench. Big dreams- I was way ahead of myself."

You would not be the first. I used nothing but pine and cheap (sometimes too cheap) plywood for a long time until I thought I had made all the mistakes I could. I've graduated to Poplar and Ash, which are more expensive than pine and, at least in my opinion, machine better and make nicer projects.

As you can see, the members here are generous with their time, advice and encouragement.

[drumpriest]

What Larry is saying should work great. I use templates often and usually cut them from MDF. I've done a ton with my Bosch jig saw. Jig saw or band saw, you'll have to smooth the cuts out on the template. Then use it to flush trim route the copies. MDF smoothes out nicely, easily, that combined with the low cost makes it a good choice for template making.

[cabinetman]

Keep in mind any nick or bump in the template will transfer to the copy. If you jigsaw slightly oversize, try blockplaning to a pencil line.



"I'M NEVER WRONG - BUT I'M NOT ALWAYS RIGHT"

[scorrpio]

Another option is chucking a sanding drum in your drill press and shaping the legs with it.

[jseklund]

Hey guys,
thanks for all the help. It's good to know that it IS partially a matter of learning skills. I was beginning to think that either my jigsaw (I got a Dewalt Jigsaw for my birthday- not the bosch. I liked the feel of it better, and it got good reviews, and I have all dewalt everything else- so my gf thought that was the one to go with. It seems good- but it's the only jig I've used. Not sure if the bosch would have made a difference.) or myself were defective. I think I just need some more practice with it. I have already learned how important it is to have the right blades.

I am going to plan and try this tonight. Thanks for the suggestions guys- I'll let you know how it goes.