While it can be built with a saber saw and hand drill as I've shown, a bandsaw and drill press can improve the accuracy of the assembly which will make for less "play" in the structure.
To print the plan from the blog, try saving it to your desktop first by right clicking on the image. If you experience difficulty printing these out, email me and I will send you a PDF of the plan.
* On the plan, there is an arrow pointing to the gap between the top and bottom outer pieces. If you are using tools that will allow tighter tolerances, this gap can be eliminated to gain another bearing surface. Beyond the small line that connects the two lines, cut both parts to the lower line.
This design as presented will hold a piece up to 4 1/2" thick. I you need to hold larger pieces, simply extend the top components from the "shoulder" of the tenon upwards.
The hole for the pivot in the shavehorse should be 9 1/2"-10" back from the front lip of the "stage". The mortise where the arm passes through the "stage" should have a tight tolerance, but move freely. If you use a heavy wood for the "dumbhead" piece and a light one for the treadle, the arm may lose counterweight when the head is in in the most forward positions, a small clamp just below the treadle can balance it to open automatically.
- Print out 7 copies of the plan to glue onto the boards, aligning with the correct side of the boards
- Get 10 feet of board, at least 4 7/8" wide and 5/8"-3/4" thick, depending on species
- Locate the parts of the interior laminate with the teeth so that you might have a second chance at cutting them, then cut them out
- Use screws or tape to sandwich the outer laminates and cut out on bandsaw (or separately with a saber saw). Cut out the capsule shaped piece.
- Remember to transfer the alignment marks from the template to the side of the pieces
- Drill 5/8" and 7/16" holes in the outer laminates and 5/8" hole in capsule shaped piece
- Lightly plane the area of overlap of the lower inner laminate, a tight fit is essential to preventing wracking
- Clamp together top and bottom laminates to check fit, predrill for screws
- Glue top and bottom laminates and let dry completely
- Screw or dowel top laminate at designated spots
- Plane capsule shaped piece until it fits snugly in opening, but slides nicely
- Set top portion onto the bottom and insert capsule shaped piece and 5/8" dowel
- Mark position of 7/16" dowel on capsule shaped piece and drill.
- Set screws for bungee cord and cut notch in lowest tooth to guide it
- Chop mortise in "dumbhead" piece and place on tenon to mark top
- Drill a hole at a 4 degree downward pitch through the tenon, clipping the line by about 1/16"
- Make wedge by shaving a dowel
- Make treadle and check the height by placing a clamp underneath it.
- Mark the desired height and drill for a peg to hold the treadle in position
- Make a mark on the side of the arm when there are only two teeth engaged for reference
- If Head hangs up when returning to the full open position, use a screw in the location shown to set the gap so that it falls easily into place
|Inner Lower Laminate|
|Outer Lower Laminates (Two Pieces)|
|Capsule Shaped Piece|
|Inner Top Laminate|
|Outer Top Laminate (Two Pieces)|