A quick job was to trim the top to length. I still need to do the left side next to the vice but this wasn't too bad. It was the first time I've ever used a tracksaw vertically, so glad I have the clamps.
It looks nice and neat now.
I was able to flush the front apron off finally. I still need to do the rear, it was only roughly cut. There's no need to do this as it won't be used or classed as a reference surface but I'm going to clean it up as it won't take long.
Next up was the vice install.
This photo is probably my biggest cock up so far.
I was so focused on getting the vice chop centered within the bearer/leg that I completely forgot to add the spacer in. In the photo you can see I have the piece of scrap to represent the top, there should be a second piece underneath this.
What this meant was when I drilled into the apron I was 44mm too high. I didn't notice until the third and final hole. It's not too bad - I've lost some time as I'm going to cut these holes out and glue in a few blocks. It was more the time lost that annoyned me. I plan on lining the vice too so it won't even be seen, but still, what a cock up. I hope this is the last one.
This is the mechanism that goes underneath. The reviews for this vice (Axminster Large Trade Guide) said the instructions were awful. You see this a lot as people are pretty stupid but they were not wrong. They are shocking, almost like taking a maths exam. You could replace them with a few lines and a template or two instead. If you've installed a vice before you'll know the deal.
The spacers were screwed with coach screws, then the spacer got screwed to the top, again with coach screws. This was pretty tough as I did it without flipping the bench. The screws were countersunk a bit to increase depth, they go about 30 ish mm into the top, which seems fine enough.
After the mistake I had a problem - not enough wood for the chop. I didn't want to waste time so I used the piece I was saving for the planing brace. By losing 20mm I was able to get a decent enough piece for the chop. Ignore the fact it's wonky here, it's not installed, just resting on the holes.
Talking of holes I should have drilled larger holes to begin with. The guides were about 20mm, I ended up drilling 25mm holes. I had to elongate these slightly - in hindsight I should have just gone bigger to begin with. I also had to use forstner bits due to the size requirements. These are naff in a hand drill. In contrast the auger bit that came with the holdfasts is excellent. If I ever do this again, I'd use one of those but in the correct size.
I did see an install of this vice on youtube where the bloke had an almost friction fit, I have no idea how it worked. The only other bit that was troublesome with this install was there is quite a bit of play in the guides, once installed they are solid but that few mm space makes all the difference when trying to fit into the guide itself.
The handle I purchased is the Veritas handle. It's pretty nice but there was two issues. First was the screws were Robertson, I don't have a bit for this so threw these away and replaced with some Torx wood screws.
The other was the end caps are a bit flimsy. The handle is solid, but these seem a bit weak. I don't remember where I got this tip but I used a couple of 22mm o-rings I had from some plumbing work, these stretched over the 30mm ish handle and mean when it drops it doesn't bang and feels so much more satisfying to use.
To attach the chop to the vice I tried using the coach screws but these didn't work. So I countersunk a few holes on the face side and used some 8mm bolts. This should be much stronger and worked fine on my old bench.
The last bit related to the vice today was to plane a 2 ish degree angle on the chop so the upper part of this clamps first (toe in?). I did this by using some double sided tape to stick a small shim on the side. You should be able to see the small gap on the right. When this passed through the thicknesser a few times the angle was planned as needed. Ignore the guide on the end grain, this was just to make sure I had the right face, I only had to take a few mm to achieve the goal. How much difference this makes I don't know - but the instructions recommended it and I know others swear by this.
As it stands the planing brace is gluing up after I ripped and thicknessed this earlier. I used the left over piece from the planing stop which was nice. The dog holes have all been drilled so I'll share that in my next update once I can run the router over them.
I have a series of small jobs to do over the next few lunch breaks with the goal to be completing the bench this weekend.