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February 11, 2010

Cutting Large Tenons for the Holtzapffel Workbench: Part I

There are a lot of good information in print and on the Internet about building the Holtzapffel workbench. Because of that, I don't want to duplicate the work of others that have done a great job in explaining overall how to build this awesome bench.

But as I was building mine, I came across obstacles I had to overcome just because of the sear size of the parts I was dealing with. So I thought I'd share some of the trickier parts in building this bench.

In this episode I look at different ways of dealing with cutting large tenons. The way that the top is connected to the base of the bench is with a mortise and tenon joint. Now cutting tenons is usually straight forward, but when those tenons are on a 3" x 5 1/2" beam, some problems can come up.

Check out how I dealt with some of those issues in this episode.

Comments (1)


That aftermarket miter gauge is a vast improvement over the stock unit supplied with most table saws,
but still isn't as rigid as a crosscut sled.

I have a dedicated crosscut sled that I use with my dado stack. An extra advantage with this is the zero clearance effect on the left of the cut which takes care of any tear out.


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