I didn't have any stock wide or thick enough for the sliding deadman, but I had plenty of waste left over from the top. I glued up two panels for proper width, to be laminated for proper thickness.
![](http://lh6.ggpht.com/_6qAGOXP58V0/S2oc2mg13qI/AAAAAAAAA94/Eo7hL6Yvg80/s400/p1310133.jpg)
Sections for the first panel. I ripped a narrower central piece so the solid widths of the other panel would overlap these, and jointed up the matching edges identified by the cabinetmaker's triangle.
![](http://lh3.ggpht.com/_6qAGOXP58V0/S2oc45XNYTI/AAAAAAAAA-A/mgVQAqfHEyI/s400/p1310134.jpg)
The two panels glued up. The one in back is the same overall width, but I had to add extra spacers because the clamps wouldn't adjust that small. I should modify these clamp rails to handle narrower widths.
This time, I did a thorough job of wiping off the excess glue with a sponge and bucket. That made cleanup a lot easier later once the glue had dried. There were no big gobs to damage my plane iron.
With the panels clamped up, I started drilling the dog and holdfast holes. All 25 of them.
![](http://lh6.ggpht.com/_6qAGOXP58V0/S2oc62AwOtI/AAAAAAAAA-E/-iNfoKkJ3LM/s400/p1310135.jpg)
I spaced the dog holes 3" apart, accommodating the travel in the Wonder Dog at the end. I used the cylindrical surform rasp to clean them out a bit.
All these holes got to be a lot of work, so after each one I spent a few minutes sweeping up shavings to rest my arms.
![](http://lh3.ggpht.com/_6qAGOXP58V0/S2oc9EDgwRI/AAAAAAAAA-M/1fRfmNMk2xQ/s400/p1310137.jpg)
Finishing the holes off from below, having just pierced the bottom side when boring from the top. I had to take off my bifocals to look upwards this close!
After completing the holes, I removed the panels from the clamps. They'd had about an hour of setup time, so the glue joints were strong enough. Then, before it completely hardened, I lightly cleaned the last bits of glue off the panels and clamps with my glue clean-up chisel. This glue drip management was a lot easier than chiseling off rock-hard bits a day later. I let the panels finish curing overnight.
![](http://lh6.ggpht.com/_6qAGOXP58V0/S3NcoRst-EI/AAAAAAAABF0/JZ4i87a4uQE/s400/p2050001.jpg)
First use of the new Gramercy holdfasts! I rough-planed one side of each panel, traversing almost straight across after first chamfering the edges.
A note about the Gramercy holdfasts. I had just gotten them recently, and I initially had some trouble getting them to grip well. They kept coming loose under the force of planing. A little checking online revealed some concerns about holding in such a thick top, but I followed Joel Moskowitz's instructions to rub around the shank with 120-grit sandpaper. I also noticed they still had a little oil on them from the manufacturing process, so I first wiped them down thoroughly. Cleaned and roughened, they now grip tenaciously.
![](http://lh4.ggpht.com/_6qAGOXP58V0/S3Ncpvb-t6I/AAAAAAAABF4/MdeQXiXinlo/s400/p2050002.jpg)
The resulting rough-planed panel.
![](http://lh3.ggpht.com/_6qAGOXP58V0/S3NcqiE9mdI/AAAAAAAABGA/GW5Eeg7qsbQ/s400/p2050003.jpg)
Winding sticks (aluminum angle iron) laid out to check for wind before starting the finer work.
![](http://lh3.ggpht.com/_6qAGOXP58V0/S3NcsExvzbI/AAAAAAAABGE/VllIiiLKAAQ/s400/p2050004.jpg)
Sighting down the length of the panel across the winding sticks. Looks good, no twist.
![](http://lh5.ggpht.com/_6qAGOXP58V0/S3NcuCBNXII/AAAAAAAABGI/O7HclhUPVpw/s400/p2050006.jpg)
The final result after flattening with a try plane followed by this smoother.
![](http://lh5.ggpht.com/_6qAGOXP58V0/S3NcwRfkymI/AAAAAAAABGQ/sl-DVUo80nk/s400/p2070031.jpg)
The two panels laminated together. The matching faces have to be dead flat to each other.
I didn't bother cleaning up this glue, since I was going to be sawing off the waste from each side.
(Continue to part 14)
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