|My new buddy.|
Impact drivers are different than a regular drill, in that they add a rotational impact (imagine if you were tightening a bolt with a wrench, and you started hitting the wrench to help accomplish this). This not only delivers a much higher torque than the motor would normally be able to apply, but it also significantly lowers cam-out (that annoying situation where the bit spins around inside the screw head, stripping the screw and potentially damaging the bit). As a result, they are also very LOUD!
With all of that out of they way, let's take a look at the actual workbench project. I decided to modify the plans very slightly. Recall in the sketch I had the bench top cut flush to the frame. I realized (since my last post) that the edges of the table do not offer a convenient clamping area, unless I used my longer bar clamps. Since I have already assembled the ends (and cut the tabletop to its final size), I can't do anything about the width, however I still have freedom in how long I want the frame to be, so I decided I would cut the longer crosspieces shorter than the bench top so there is at least a lip to clamp onto on the edges. I decided to leave a 1-1/2" lip on each end, so I measured the length of the top to be close to 47-1/2", so I made a mark on the long crosspiece at about 44-1/2" (after squaring up one end as described previously for the short crosspieces). Once measured, I placed my cross-cutting jig as shown in the below photo, and cut the wood to size.
|With the desired length marked on the wood, I can use my cross-cutting jig to cut.|
|All four pieces were cut to the same length.|
With this glue-up, I wanted to be a bit more careful. One of the problems with the end frames was that after adding glue, it was very difficult to keep the piece from sliding around while drilling in the screws. So to begin, I put the ends on their sides, and clamped the longer crosspieces in position as shown below.
|The crosspieces are clamped in position so they cannot move around.|
|I insert a pilot hole into each contact area to help with alignment once glue is applied.|
|I apply and spread glue over all contact surfaces.|
|Inserting screws into the pilot holes imposed alignment of the pieces.|
|Putting the piece in place after applying glue.|
|Additional screws are added to apply pressure while the glue dries.|
|The finished (almost) frame!|