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I mentioned in the first post that Im using some off the shelf hardwood for the bench frame; this was great for my budget but not ideal for my hand tools. Because it was dimensioned at the mill (and I use that term very loosely) I have to re-dimension it all again before I can start laying out my joinery. Theyre definition of square must be a little different than mine!
Whenever possible I like to lay out my joinery in groupings ie: the legs get clamped together and the mortises for the cross stretchers are laid out together. This will help keep things consistent and insure continuity between the pieces. I use a pencil to mark off the thickness of each component and then a deep scribe line with my knife for the joinery. 
All of the joinery for the bench frame is mortise and tenon except the front legs into the top apron by way of the slip joint.(refer back to part 3) The Ipe is close to 1 1/2" square so Ill follow the rule of thirds and lay out 1/2" mortises. I begin at the top of the back legs where they meet the bench top. I saw a tenon into the rear leg tops and chop out the mating mortises. Over in my shoulder vise I get out my favourite back saw and make some dust. You may notice in the pictures my set up for sawing the tenons- I hold them in the tail vise and have my bench hook next to it on my bench top. This is an efficient set up when you have a lot of tenons to cut. I start by ripping down the two cheeks and then turn the workpiece and rip the other two shoulder cuts. Then its a simple matter of unclamping and sawing at the bench hook without ever having to take a step. Ill get both tenons cut and then back into the tail vise to pare down to the scribe lines. 
From there Ill use my mortising chisel to chop off the little wings left between auger bit holes and square up the ends. Ill clean out the bottom and get ready for a dry fit. The brace and bit method of cutting mortises is a fast and accurate method but I should also mention when you first lay out the mortise its a good idea to scribe in a center line. This will give a point of reference for the bit to find center when drilling. The first dry fit shows me that I need to remove a little meat off of the tenon. This is another one of those wood working myths- tenons dont have to look pretty! I know we see them in our favourite woodworking magazines, all crispy and shining like a new dime but really-? 
The bench now has four legs standing proudly, although still inverted on my bench top- I decide to address the bottoms of the legs and the feet. Its a natural progression, but I dont give the sequence too much thought. I suppose you could cut all of the legs first and then move onto all of the stretchers... I enjoy watching a work piece come together and at the end of my work day I like to see what Ive accomplished. So I started with the legs and then onto the feet; at least Ill be able to stand the bench upright and get a sense of where things are going for tomorrow!
O.k. so the phony headline on the last post was a little mis-leading. You thought you were going to find out some top-secret finishing techniques I have locked away in some old turn of the century wood working encyclopedias, but no, you only got a mellow-dramatic tale of one small Block Planes journey through wood life in my shop.
Put it aside because Id really hate to hear that you burnt the tips of your fingers. Now the secret weapon; the Sanding Aid that will change the way you think and work with wood. Ill include specific dimensions at the end of this post. The Sanding Block. An approximately two and a half inch squared piece of hardwood, ( I used Oak for mine ) take this small off cut and reach down onto the floor of your shop. Scoop up a handful of shavings left over from the Smoothing plane earlier. Place the pile of shavings on the work piece and compress it down with the block of hardwood. Rub vigorously around for as long as you can stand it and step back. Look at the gleam rising out of the wood grain! Incredible isnt it. I usually follow this step with an oil and varnish hand rubbed finish. Amazing eh?
