So the project took a little turn today….....................
The top is glued up into 5 sections, was shooting for four sections but it didn’t work out that way. The sections are pretty flat and square – just need a bit more fine tuning of the mating faces….....
I guess I’ll take some heat for this, but it dawned on me I still have a quantity of extruded aluminum piled up and waiting for a purpose – same stuff I used for my router table. Also have another set of those super sweet industrial casters that will raise onto solid rubber feet, making the bench rock solid.
This wasn’t the original plan, but it makes sense to me – the basement floor is horribly unlevel so the bench will always be true flat and the base will not rack – at least not under my power. The bench is really about the top so this works for.
Keep in mind, that I got this material at a very low cost, so this is why I chose to use it. I don’t think most folks would spend the dollars to purchase for this purpose. This material is Parker (IPS) which is similar to 80/20 brand.
These are the early photos – and much more work to come:
The notch on the right end will allow clearance for the tail vice:
I figure I will secure the top with 4 of these slotted “L” brackets:
Here is the top (still in sections):
I should note – the aluminum and all the components were used and VERY dirty. They were used in a rubber roll grinding area, so super sticky rubber dust is coated everywhere. Here is a castor as received and one that I cleaned up:
Here is shot of the bottom of the castor and you can see the rubber pad that can be lowered to the floor using the red toothed wheel you can see in the previous photo:
This frame design does not require any corner brackets, instead, all the holes are cross drilled and uses M8×1.25 cap screws with retainer brackets to holds the joints together – here are some photos on how the joints work:
Still to go:
- Glue the top together and flatten…
- Add a 6” apron around the top
- Add the vices
- Build some storage stuff below….
It looks a bit plain right now, but I think it will fill out with time.
Also this is whats left of the aluminum pile – so not you won’t have to suffer through too many more of unconventional builds….:)
Thanks for looking,
-- Jeff - I have not failed. I've just found 10,000 ways that won't work.