Friends –

I’m taking delivery on a new table saw next week, which will require some re-configuring of a few things.  I originally built my work table to function as my primary work and assembly area, and as a co-planar outfeed table for my router table, saw, and planer.  When I built the table five years ago, the idea was that I could simply unscrew and remove the top layer of 3/4 plywood and replace it when it got too worn.  However, over the years I’ve installed a ton of drawers, fixtures, dust collection piping, and vises to the underside of the table to the point that it would not be practical to go that route, so I’ve decided to just add a new sheet of 3/4 something (probably Baltic birch or other premium plywood again) and start fresh. However, I would really like to take this opportunity to make this new surface as flat and level as I can.

My shop floor is crazily out of level, and it took forever to get it so my work table is more or less level (bubble within the marks in every direction).  Over the years of adding drawers full of heavy tools, installing and then removing casters, etc., the top is currently not flat enough to do things like use it to reference a flattening jig or anything else that requires dead flatness.  I’m thinking that before I screw the new sheet goods to the top, I could flatten the current plywood top with some kind of self-leveling epoxy or other leveling compound, and then screw the new top to that.

The idea would be to treat it like like I’m pouring a slab: fasten something flat around the perimeter of the table, seal it with tape or caulk , and then pour the least amount of epoxy/compound I can get away with, I guess until the highest point of the top is submerged.  I don’t think it would need more than 1/4 inch or so. I would then screw in the new sheet goods from the bottom, giving me a level and flat surface to align the other tools to.

Attached is a photo of the shop. Any comments about this plan or recommendations for which materials to use would be appreciated.  Thanks!!