I have been giving some thought to replacing the bench top on my small workbench. I have been formulating the lumber I will use. i will continue to use construction grade Douglas Fir, but I will not use 2 by 4s like I did when I built it from a Woodsmith plan. I deviated from the plan by making the benchtop longer and placing a vise on the front left side.
Instead of 2 by 4s I will use either 2 by 8s or 2 by 10s and rip them to about 3 inches or as wide as I can get them after milling them flat, square and straight.
The actual dimensions of 2 by 8s and 2 by 10s are 1 1/2” by 7 1/2” and 1 1/2” by 9 1/2’ respectively. After splitting and milling this lumber four square, flat and straight I believe I could maximize their finish sizes to about 1 1/4” wide by 3 1/4” tall. i would make the top a bit longer.
I also want to have the front of the bench-top so it is flush to the front legs of the workbench. I have to give this feature some thought.
My bench-top before I sanded and planed it flat.
My bench-top after sanding it.
I intend not to drill any dog holes. Instead I will make bench-hooks. One I already have that I use for 45 and 90 degree cuts and shooting with a plane. I like Tommy Mac’s large bench hook that he uses for hand planing hardwoods. I will give a link where he shows it, if I can find that video.
This is Tommy's video on the workbench he built in Season 3. Towards the end of the video he shows his benchhook.
I also like the small bench hooks that were demonstrated by Roy Underhill while at Lie-Nielsen’s Toolworks.
-- --- Happy Howie