Torsion Box Countertop, 40" x 14 feet

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Project by SawdustTX posted 10-01-2015 04:16 PM 4927 views 1 time favorited 2 comments Add to Favorites Watch

Needed a 40” deep by 14 foot span countertop to support over 300 pounds of Audio gear in our church. The original builder installed counter had sagged an inch in the middle, so I wanted to build something seriously stout to replace it.

After much reading on LJs, I went with a torsion box of 3/4×1 1/2” ply ribs spaced 8” on center with half-slot joints, and sheathed in 3/4” ply top and bottom. Assembly was made more challenging by how warped the plywood was two days after bringing it home from the box store. Love the torsion box design – it ended up flat as a pancake!

I added some screw blocks within the grid so I could screw clamp the middle of the skins down during glue-up, and for wire pass-through holes.

To be able to transport this beast, I built it in two 7 foot long sections, then joined them onsite at install, with a center post support recessed 8” back from the leading edge of the counter.

Formica laminated, with a final one inch wide “bridge” strip installed after the counters were joined to create a seamless surface.

Next time – I’ll use solid wood for the ribs, and thinner skins, probably 1/2”.

Now I need to find time to make a couple torsion box tabletops for my shop!

Made a finger joint type jig for my miter fence and cut the half-slots with a dado blade.

2 comments so far

View HillbillyShooter's profile


5811 posts in 1712 days

#1 posted 10-02-2015 01:20 AM

Impressive work for a fine cause. Thanks for sharing.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View Roger's profile


19711 posts in 2224 days

#2 posted 10-27-2015 11:40 PM

That is a humongous counter top

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed.

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