[DougW]

I'm well into a project that needs 2 countersink holes (flat bottom) drilled into 2X6 boards in precise locations. The holes need to be 2 5/16 in diameter and 9/16 in deep. I don't believe I will EVER need to drill any more 2 5/16 holes in my life, so I am rebelling against buying a $16.50 drill bit.

The router should do fine, but how do I make a round template of a specific size to use? I've got an idea or two using my lathe, but would enjoy any suggestions you may have.

thanks in advance. ...Dougw

 

[DougW]

Thanks for the ideas, and sorry for not mentioning what I was doing.

I'm building my dream workbench and the vise I'm installing has metal guides for the rails that are inset into the wooden jaw face. They need a 2 5/16 hole about 9/16 inches deep. Today I'm leaning toward buying a 2 3/8 sawtooth bit that will work for clocks I can buy. At least it is an investment toward future projects.

So I don't err twice in a row, the bench is constructed of spruce. The top is about 2 1/2 inches thick and 28 X 48 in size. Legs are about 2 1/2 by 4 1/2 rectangular. There is a planing dog inset into the top. I've just completed the leg vise on the front (using a Lee Valley end vise screw) and am installing a Lee Valley large vise on the end. I've got a bench dog and some bench pups to complete the current design and adding some flexibility. As planned I should be able to clamp up to 30 X 48 flat on the top with no problems and just about anything vertically on the front. One final addition will be a deadman support that slides across to complement the leg vise.

The design draws heavily from an 18th century plan I found in a magazine recently. The mag isn't with me or I'd quote the issue.

...Doug

 

[DougW]

Hi Chuck.
Sorry to hear about your vise. I'm very happy with the Veritas models, especially now the bench is complete. The front vise (on the end of the bench of course <grin>) is a bit stiff, but then I never liked a sloppy vise and it will work in over time. The tail vise mechanism is now a leg vise and capable of holding something about 9 or 10 inches thick easily.

As for the holes... I cheated. I found the standard inset clocks take a 2 3/8 bit which is acceptably close to the 2 5/16 size for the guides. I found the round hole and the flat side of the guide gave just enough adjustment to allow centering the guides and adjusting the support they give... probably why my vise is a bit snug.

Today the bench got two coats of Danish oil finish. Tomorrow if I get a minute the top gets some paste wax... and I'm done! Now just to convince the wife to pose in a bikini for pictures they way they do for custom hot rods...

Doug

 

[DougW]

I agree with what you say. I opted for a single application of Danish oil based on recommendation in Woodworking Magazine (Rethinking Workbench Designs, Autumn 2005). They tested several mixtures and tested them for use, glue adheason and stain absorption. Danish oil/wax combination was second place in their tests and first in convenience.

While I would really like to devote the bench only to construction I have to use available space for assembly and finish as well. If I could afford the former I'd have left the wood unfinished.

...Doug