Organ bench - 2 Print E-mail
Written by Vidar Fagerjord   
Monday, 20 July 2009 20:48
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Update 24.07.2009


I decided to do a few design alterations. The inset panels in the legs are gone - it would be difficult to get the slot cut since I've never attempted it before. Oak is an expensive wood to experiment with... Anyway, the good'ole mortise and tenon joint is very strong, and with some reinforcements here and there I should not run into any problems.

Using the router and a straight cutting bit, I cut the mortises in the columns. Instead of squaring off the mortises (since the router bit is round, you can't cut squares...), I simply rounded off the tenons. Here's some images of the different areas.

First off is a detail image of the top of the columns, with the frame part in place:

As you can see, the mortise was cut too deep, so I'll have to fill that gap with a piece of wood.

Here's an image of the tenon - a bit difficult to see, but there it is:

To start rounding the tenon, I use a file at 45 degree on the edge. I then file each new edge "in half" - and the basic shape is established. From there, it is very simple to round off the tenon.

I placed the various parts of the legs so that you can see the different joints:

As you can see, I used the router to cut the mortises for the middle horizontal part (which the foot rest will be mounted to). It is important to get a snug fit in a mortise / tenon joint, so cut your tenons a bit too large and sand or file to fit. I am going to use wooden dowels and screws to mount the foot to the columns. This means that I can go back and modify the bench should I need to (if the bench is too high). Should the bench be too low, I can simply make spacer blocks and mount them using wooden dowels under the foot. I am also thinking of installing adjustable screws so that I can compensate for uneven floors.

The router is the most versatile tool you can have, so buy a top-notch model! Here I am cutting the stretchers that will run between the legs:

Multiple passes along a straight edge, increasing the depth for each pass. And within minutes, you have a PERFECT cut! Some light sanding, and you're done! It would be easier to use a table saw, but I do not have a good quality one. Anyway, I needed to practice the router...

I just had to check how the bench and the pedal board will fit, so I did a little test setup. I'll let the images speak for themselves (description under each image):

I used clamps to hold the pieces together. VERY wobbly, but I managed to sit on it
(over a leg, not in the middle! there was no support under the seat)

Showing the curve in the front...

The pedal board with the middle 5 pedals in place...

A view I'm going to get used to! Can't wait!

I placed the curved toe board and the side panels to get an idea of the look.

Note: The side panels and the toe board are NOT finished yet!

These puppies will be in my living room soon!

The bench is very fun to make - and I am going to finish it before I do more work on the pedal board. I actually do need the bench ASAP, since I only have a dining chair in front of my keyboards. Too low to be comfortable...

A nice, not planned feature of my bench: The foot rest will have a slight curve in the front. The cupboard top, which my seat is made from, actually had a slight curve at the front. Nice!

Tomorrow I'll take a small trip to my local tool-pusher and get two very long clamps so that I can apply pressure while I'm gluing the bench. I also need to do a lot of sanding and figure out how I'm going to shape the two pieces that the foot rest will be mounted to. They are about 10mm too thick now, but that could be used to my advantage. We'll just have to wait and see. Well - you have to... 

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