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

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

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.

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

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

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