making a deadflat workbench top

The dead-flat top table that I want to build soon is the one from Wood Whisperer video episodes 18 & 19… http://thewoodwhisperer.com/

Whatever you choose, please post it as a project!

-- JC - Central PA - www.affyx.com

A dead flat bench is only as good as the floor it’s sitting on.
If your floor is uneven then everytime you move it you will have to re-shim it to keep it flat.

I would think that a table that size would flex unless you have a great base for it. I would worry
more about that the what you actually end up using for the top.

-- Gary, East TX -- The longest journey begins with a single step.

Ernie – I have seen “workbenches” that large, but they have all had massive legs and generally had shelving/cabinetry underneath. I would view a table this large as more of a work assembly station and not so much a “workbench” in the traditional woodworking sense.

Do you plan to put on any face and/or tail vises?

Also, how do you plan to put these three pieces of ply or mdf together. Screws or glue?

I also agree with Gary’s thought on the flooring. My garage floor is very uneven and I generally have to shim everything to come up with something close to level.

-- Betsy - GO BUCKS!

A double layer of MDF makes a fantastic bench top! The only suggestion I have is to glue the layers together, then edge the sheets with 1 5/8” hardwood, keeping the hardwood flush wih the bottom edge. This will leave a 1/8” “lip” around the top. Can you guess what that lip is for?

Put a sheet of 1/8” hardboard as the “top layer”, and the lip holds it in place, giving you a perfectly flat top. When the hardboard gets all messed up, just give it a scrape and flip it over…voila: New bench top! When you’ve done in both sides (you will….) Just replace it with a fresh sheet. At 6 dollars a sheet, it is a good investment :)

Hope this helps!

Ryan

-- If you can't set a good example, at least serve as a horrible warning... www.rarewoodcreations.com

Torsion box!

-- Maplewood, MN

I second JC’s comment – Marc Spagnuolo’s assembly table is on my “to do” list if I ever get around to finishing the shop re-hab. Check out thewoodwhisperer.com I’m pretty sure the plans were also published in FWW. Marc’s also an LJ member. Check out the podcasts on his site, they’re pretty entertaining.

-- I've cut that board three times and it's still too short!

See my bench in my projects. It is 42×70 and has a a top that is 2 thicknesses of particle board and one of 3/4 Poplar ply. Works great.

-- Thos. Angle, Owyhee Design, Oregon

Mine is not as large as the ones above, 3×5, I got this design from a local furniture maker. I built a cabinet under this and put heavy duty casters under it. The top starts with a sheet of MDF cut to 3×5, the second layer is scrap mdf around the edges and spaced evenly to allow some spaces, to cut down on weight. these pieces get glued and screwed. when the glue dries remove the screws and add another sheet of MDF. Glue and screw this. remove the screws when dried. flip it over and add oak or poplar or maple along the edges and chamfer. cover the whole thing with several coats of poly and voila. new table top. mine is over 5 years old and probably has another 5 years of life. It’s a little wide, but it does give enough room to work and assemble. The poly protects it very well. The torsion box design is on an episode of woodworks. I believe Marc apprenticed with David Marks, This looks like a great design for an assemble table.

-- Joey, Magee, Ms http://woodnwaresms.com

I agree …mdf, torsion box design, and Mark did it well, check him out and follow his lead