The author has created an affordable end vise and sanding station, utilizing a solid core door and recycled pallet wood for the bench itself. This type of project is ideal for those who are looking for a versatile workbench that can handle a variety of tasks, such as clamping and sanding.
The first step in creating this project is to acquire the necessary materials. In this case, a solid core door is used as the base of the bench. The author suggests finding a door that is at least 32 inches wide and 80 inches long to ensure that there is enough space for clamping and sanding. Alternatively, a sheet of plywood could also be used as the base.
Once the base is acquired, the author recommends using recycled pallet wood to create the bench’s frame. This is a great way to repurpose materials that might otherwise have gone to waste, while also providing a cost-effective solution.
To create the frame, the author first creates a box around the perimeter of the door, using the pallet wood. This is done by cutting the wood to size and screwing it into place, using the pre-existing holes in the door as a guide. Once the box is complete, the author adds legs to the corners, using more pallet wood to create supports that are screwed into place.
The next step in creating this project is to add the end vise. The author notes that the most expensive part of any vise is usually the screw, which can cost anywhere from $20 to $50. However, the author found a way to create their own screw for much less by using a simple threaded rod and some nuts. This method allows for the creation of a sturdy and functional vise without breaking the bank.
To create the end vise, the author first drills a hole through the end of the bench, where the vise will be located. This hole needs to be slightly larger than the threaded rod that will be used for the screw. Once the hole is drilled, the author inserts a threaded rod through it, leaving one end sticking out. They then add nuts to either end of the rod, tightening them together to create a makeshift handle.
To finish the vise, the author adds two wooden blocks to the end of the bench, which will be used to hold the workpiece in place. These blocks are attached using screws and are positioned so that they clamp down on either side of the workpiece when the vise is tightened.
Finally, the author adds a sanding station to the bench. This is done by attaching a piece of plywood to the top of the bench, securing it with screws. They then add a hole to the center of the plywood, which will be used to hold a sanding disc. The author also creates a simple tool rest using more pallet wood, which is mounted to the side of the bench using screws.
Overall, this project is a great way to create an affordable and functional workbench that can handle a variety of tasks. By repurposing materials like a solid core door and pallet wood, the author has found a way to keep the cost of the project low, while still creating a high-quality work surface. With the addition of an end vise and sanding station, this bench is versatile enough to handle a wide range of woodworking projects.
