This started out with me wanting to build some speakers and a couple sub-woofers and pretty much snowballed out of control to me picking up a woodworking hobby along the way :-)
So I basically took the mobile part out of it, well it has casters on it, but I wouldn’t want to try to get it in a truck. I’ve also optimized it for a track saw. It’s a full 4’ x 8’ x 39” high.
Bottom is 1/2” ply for the top & bottom, vertical members are 3/4”. Top sides (with the rectangular holes) are 1/2” ply, the inner ribs are 3/4”. Top is 3/4” Oak plywood, with T-tracks and sacrificial 3/4” MDF pieces on top of that. Casters in the 4 corners, leveling feet under the verticals (8 legs total).
Tracks are positioned so I can break up sheets and they’ll be fully supported (always able to have less than 1/2 the cut-off hanging off the bench) or clamped if desired.
I don’t own a table saw, and don’t plan to (shocking I know). Built with tracksaw, dowelmax jig, drill press and 3” holesaw, router, and my miter saw.
All the pieces that could be were stacked and cut at once with the tracksaw/miter saw. Anything that wasn’t I picked the smallest piece and flush trimmed the others to match with the router.
It’s doweled (one about every 5” with a screw inbetween dowels), screwed, and glued together. Doweling it really helped to pull everything square during assembly, and I stacked tops & bottoms and sides together and doweled them all at once to ensure everything came out square. It’s dead flat excecpt for a .02” dip in the middle at one end, so all in all the method worked well, even if it took some 400 holes lol.
If I had to do it again I would just punt and make everything out of 3/4” oak plywood (from big box, not cabinet grade). I’ve included a couple pics of it being used. Having a large worksurface and the storage under the top to put things you need but not right now is fantastic. As you can see the holes work great to store clamps, and there is plenty of room underneath to store all my other tools without even trying to organize it. I’m sure it will fill up eventually.
The T-tracks work well enough, and it’s very easy to pull the truck up, slide the sheet from the truck to the bench, cut it up and not have to handle large awkward heavy sheets and try to support them. The mdf inserts let me cut sheets without having to look for scrap pieces to get it up off the table.
Anyway, so far I’m very happy with it, and glad Ron made the plans available.