I purchase 30 2x6 boards of used SYP lumber. This looks to be either old palletts or building material of some sort. There where lots of staples to remove, but all the nails where gone. In fact the boards probably where 8fters originally now they come in around 77". The nice part was they were about $1.50 per board.
Day 1 11/2/08 (1+hr) -- Face and edge jointer 6 boards, all about 36". The wood seems to have a lot more defects then I remembered. Also they are closer to 1 1/2" to start then 1 3/4" , looks like 30 boards won't be enough. Spent a long hour in the shop.
For a change of plans I will use 4 boards to make each leg; again more wood then I originally guessed.
Day 1 session 2. (45min) The kids are in bed, I face an edge 4 more boards.
Day 2 11/3/08 (1+hr) Got the last 6 boards done for the legs, even ripped the first one to width (4") on the table saw. My guess is the legs will be approx. 4x4 when I am done. Pretty happy with the way the first ripped piece looks.
Day 3 11/4/08 (1hr) I am pretty motivated at this point, getting a lot of time in the shop. Ripped the other 15 pieces to 4", this is the most I have ever used my table saw. Pretty happy with the results.Day 4 11/7/08 (1hr) Planed the 16 leg pieces to final thickness <1 1/4". Made lots of wood chips, filled the shop vac twice. Pleasantly surprised by how good the wood looks. It looked awful in the beginning. My new estimate is 16 more boards, hopefully can get there next weekend.
Day 5 11/8/08 (2hrs) 2 hours is a lot of time in the shop for me. Getting downstairs around 8pm doesn't leave a lot of time plus I am tired. However I get some afternoon time today. I cut the leg lengths 8 pieces at 31" and 8 pieces at 33". The long pieces will become the 2" tenons to attach the top. Did the first 2 glue ups, I had a lot of squeeze out and they didn't feel like I had them aligned as well as I should. This way my first glue up, with the exception of the class I took. (see photo)
Day 6. 11/9/08 (30min) Finished gluing the other 2 legs. These were better then the first ones. Less squeeze out better alignment.
Day 7 11/11/08 (1hr) Chiseled away some of the "extra" glue, ran the legs through the jointer and planers to make them square. They seem to be pretty square however there is slight deviations in the lengths. Will get to fixing them when I start the mortising.
8 trips to the shop 8 1/2 hours of quality time and I have 4 legs mostly complete. Things are looking good. This may not be the showyest bench around but I am guessing it is going to be a lot better then what I currently have.
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