Woodworking Workbench Plans

I f you are reading this page then it is likely that we have something in common. We both like working with wood.

diy woodworking

diy woodworking

In fact we probably both LOVE working with wood.

I am also going to assume that you have a big problem.  You see I had the same problem in the past so I understand.

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This is a 150 grit sandpaper. You will find that it sands down very fast.

Just about 30 seconds of sanding and it’s starting to look really good. Next we’re going to figure out where we want the inlay. And you want to choose the spot of the ring that’s the thickest.

Because we’re winding and winding it on the inside of the wood it ends right here, and on the outside of the wood ends right here. So right here is the thickest part of the ring and that’s where we’re going to put the inlay because when we work on it we are sanding it down a lot and we don’t want it to get really thin.

So if we did on the thinnest side and sanded that down a lot and we it would be really thin here and really thick on the other edge. So pick the thick edge of you are going to do an inlay.

This is the brass that I use. This is just hobby brass. You get this at hobby stores. Almost all of them have it. I think he can even get this at Home Depot. It is thinner than the wood veneer. It’s easy to cut. You can use tin snips, but these tend to bend the brass and leave impressions. It’s better if you can have some like this that are actually more like finger nail clippers.

Because they pinch the brass and won’t warp it very much, The triangles we are cutting out for the Tri-Force are really small so each triangle you see here is actually the whole Tri-Force. We have to cut those into smaller sections. Here are 3 triangles. It’s enough for three rings because each one of these triangles has to be cut up into3 smaller triangles. It gets really difficult in the end so what I suggest is to cut up a ton of triangles and then you will find three that match. The correct size, I just eyeball it.

It’s a lot easier…cutting a bunch of triangles and finding ones that match, than it is trying to make three of them perfectly. Here are all the triangles I cut so far this one’s big this one’s average that one is small.  I’ll keep cutting until I have three that look about the right size. Then I will hold them in pliers and file down the edges. So that all three match, It’s hard to get the angles exactly 60ºon all sides.

So I file them down a bit and when I have three that look about right then we’re good. If you don’t have a file, use sandpaper and sand down the edges. I hooked up a macro-lens so you can see what we are filing off on the edges. It’s hard to hold still but here you can see the edge. When I use clippers it puts this bevel on it so I’m just grinding that down so that it goes into the wood straight and clean.

Then position them so that they are all lined up the way you want them on the ring just to make sure that it looks right. Maybe one of them needs a little bit more filing.  Maybe one of the triangles is a little bit off. Once you’re happy with it then keep the triangles in that shape and we’ll move on to cutting out the ring. This is the part where it transitions. Where the end of the wood is. 

Sand that really smooth so that there’s no bump. For this part you want a brand new blade. If you use an old blade it will be very difficult. Try to keep the tip of the blade from breaking. To pick these up get the tip of your finger a tiny bit wet and they stick right on. When it is where I want it, I push it down hard with my fingernail and scratch on the edges tracing where I want to cut. There’s the triangle. If you have a sharp blade it’s not going to be very hard to dig this out. Just don’t twist the blade or you may break off the tip.

This is not a normal working position for me. I have the overhead light really close. I’m trying to keep this on camera. Just slowly shave out the little bits. Flick them out. You want a tight fit. You can just smash the wood. Make the wood bend around the metal. That’s good. It needs to go a little bit deeper. You can see at that angle it fits right in. I’m going to do all the others and we’ll skip ahead.

The top triangle is a little too big. Let’s file that down. The top one needs to go deeper as well. How do you glue it in? I want to keep these in the same position I took them out. A little bit of super glue. I think I got it in wrong. Flip it over. This is the part of project where you pretty much are gonna clear fingers. Let’s put in a little bit more. It does not want to go.

There we go. Now the next one. Smash it in as flat as you can. That does not look right. Let’s take it back out. Yeah, that’s better. Let’s put glue back under there. This thing is flicking around. It seems to fit right.  Let’s just smash it in. You want to get it lower than the wood, because you can sand the wood down. Smash it in and now we will wait for this to dry. It only takes a few seconds to dry.

I will use this same rough sandpaper. You’re seeing it down so that the world and then you are sanding it down so that the wood and the brass are flush with each other and you can actually send the brass down as well. It’s not that hard of a medal. This part of the process also helps Sanding also helps clean up any scratches in the brass that you might have made when you were cutting it or pushing it in.

I can see right here is a bit of blue. Once all the brass shines the same way then you know you are done. There it is. Now I’ll go down to smaller grit sandpaper. What is this 400?I’m going to do a lot of sanding now. This is 220.Then I’ll go to 400.  You can keep going into the 1000’s if you really want to shine this thing up. I’m going to balance the ring out. I put this inlay in but I can see that it’s set a little low.

This ring is thicker than I want. Size the height of the ring after you put in your inlay. You can see how the Tri-Force is more centered in the ring. Don’t worry too much about it; just send it to the right spot. The last sanding was about 600 grit. Now I will to coat the inside with superglue.

What this does is, it’s going to penetrate all the way into that you can get this ring soaking wet with water and it’s not going to get ruined. Then I’ll do another sanding and then we’re going to wipe it again with a finish coat of glue. I just want to make sure the whole thing has a nice coat on it. Soaked in all the fibers. That will keep it…waterproof and strong. Waite A few seconds to let this dry.

Then one more sanding and a polish coat. You can polish coat it this way. Put some superglue on a rag and smear it. [Don’t use wool or cotton cloth because it may burst into flames][No, I’m not kidding]What do you think? I think it came out pretty good. Let’s compare it to the first one. This first one I put a spray coat on. It doesn’t feel that nice on your fingers.

The same lacquer that we used on the swords, it feels kind of grippy/rubbery. But the superglue as a final coat is nice and smooth. Don’t use a lacquer. I wouldn’t recommend it. Here’s a second ring. Let me show you how to fill this in another way. I cut out all the Tri-Force shapes. I willshow you on this camera here. This might be an easier way free to do it. I hollowed all that out just by eye.

I didn’t match up any triangles. It’s a lot easier to do it like that. I’ll show you how we are going to fill this. We are going to grind the brass into a powder. You can get brass powder by making it yourself. You want a fine file, not a rough file, to get fine bits of brass. You can use plumbing fittings. They are brass. If you want other metals like copper…We will make a pile of copper, aluminum and brass.

woodworking jigs

woodworking jigs

woodworking joints

woodworking joints

woodworking kits

woodworking kits

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woodworking machinery

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woodworking magazine

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2 Responses

  1. July 17, 2017

    […] love hearing that kind of stuff. Awesome, keep sending the photos […]

  2. July 17, 2017

    […] bit more. And this is what we are left with. You can see there are no real gaps in between the layers of wood. And I’m not letting go on keeping this very […]

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