How to make a Split-Top Roubo Woodworking Bench for under $200 part II

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I got around to cutting off the ends of the workbench today. Since it was 5" deep I had to use a circular saw and cut to its maximum depth, then flip it over and do the other half, and finally cut through the last 1-1/2" with a handsaw.

 

Before doing that, I mated the two halves together and clamped them. Then, I used a straight edge that was placed exactly 90 degrees to the long side. And finally, I cut them as one piece.  After unclamping, and flipping, I repeated the same procedure.

There is really no other way to do a cut such as this. It is too deep and too long for a miter saw. And at 80" long, and about 100 pounds each, the top pieces are far too unwieldy for a crosscut sled.  This is a good opportunity to practice circular saw skills. A good quality sharp blade, and a rigid straight edge, will give you perfect results, just cut slow and steady, and make sure to keep the edge of the saw against the fence the whole time.

I can remember the first time I had a table top that had to be done this way, it was a 2" thick solid oak table and I was so nervous to put a circular saw to it. It just didn't feel right after using higher quality shop tools all week. But, I was pleasantly surprised, and it came out just fine.

You can also use a track saw if you have one. I have used them and they are great. But I just used my trusty straight edge here.

Anyway, after the top was cut to length, I dressed up the ends with a belt sander to remove the saw marks, and a random orbit to remove the scratches left by the belt, and I think it came out ok.

Moving on, I had glued up the legs and rails last night. This way I can mill it down to a 4" x 5" size. I think that'll be beefy enough, and it will look like it belongs under that hefty top.

So, today I milled all of them down and cut them to length.

I even started the mortising process by doing the layout, and cutting one.

 

 stay tuned....

Also, If you would like to learn a technique, such as dovetailing, or any woodworking skill at all, or if you want to see a specific project built. leave me a comment. almost all of my builds come from viewer requests.

Lastly, if you gained any knowledge from watching my woodworking instructional videos, and you'd like to donate a $1.00 to help support my channel, check out this link:  Help here.


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  • Idoneam Fabrilis on

    Dr. King, I hope you’re going to post a video of this build. It’s one of the projects on my list and I’m sure to learn lots of useful skills watching it. Your table looks really nice and it looks like it’ll turn out stout like a dreadnought!


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