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Reply by phlepper

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Posted on Joining two MDF slabs, face to face, and getting it flat

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phlepper

21 posts in 1857 days


#1 posted 1428 days ago

Mark,

I created my workbench top the same way (actually have done it four times now for different benches). I just pre-drilled screw holes from the underside and then applied the glue and used the screws to “clamp” it. Once dried, if you don’t want the screws, you can just remove them. Mine were as big as 6’ x 24” and haven’t had any problems. Ran 1×2 along the outside for edging (attached with biscuits and glue).

As for a caul, it’s been a while since I made mine, but i just used 2×4 and taped a 1/4” spacer to it towards one end and ran it through the table saw with the “spacer” edge against the fence (and the fence set at 3.5”). You end up with a board 1/4” shorter or so at the end, tapering to 0 at the center. Make sure you tape the spacer so that it doesn’t end up off the fence before you get to the middle of the board. Flip it over and put the spacer on the other end and do it again. Do that for two pieces and you have a caul. Took no time at all and no special effort. Ran off two sets of them in less than 10 mins. Have used them many times, work great.

-- "A hammer in search of a nail..." (thelepperts.wordpress.com)


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