Mark Schofield e-newsletter regarding plywood benchtops – a better method
Here’s the link for those who missed it: https://www.finewoodworking.com/Community/QADetail.aspx?id=29953
I have a better option than laminating 2 sheets of expensive (void free, lots of layers) plywood together. Where I live, 2 sheets of 8×4 Appleply will run me ~$240. The method below will cost <$100 in materials.
Build a torsion box using 2x4s or strips of plywoodfor the framing & use cheap plywood on the bottom and single faced ply or MDF on the top (screw and glue everything). This structure will be much more resistant to flexing than 2 sheets of ply sandwiched together. For the dog holes, there is an easy way to create square holes without ANY drilling. Take two 2x4s and one 1×4 (make sure the 1×4 is the same width as your bench dogs). Cut the 1×4 into squares and then screw and glue those squares between the 2x4s. When making your ‘squares’ you really want to cut them at a slight angle (a few degrees off of 90) so the bench dogs will be slightly toed in toward the vice face when everything is assembled. Lag bolt the dog hole assembly to your bench top & add another one on the back side if you need 2 rows of dog holes. You can also use 2×6 and 1×6 material if you like overkill. Below is a picture of my bench that shows the dog holes clearly. Note that I was not done chopping the end vise hole when this picture was taken. Finally, this idea is not mine, I got it from a magazine 10+ years ago and the bench is still going strong.
Greg
Replies
Greg..
My best bench top was a slab of about 2 inch thick Purpleheart.. I sold or gave it away long ago. I forget what I did with it. That slab cost me about $150.00 US at the time (I had money then.. No longer). I bought it because it was at my local OWL Hardwood (Chicago) supplier for a very long time.. Noboby wanted it? I do admit that the slab was a bit narrower than a 'So Called 'standard sized' bench...
I have made a few benches for the local woodworkers out of the Honeycomb doors.. Yes.. I realize that many, BUT the Most Expensive doors, have the Honeycomb, as is imbeded Cardboard..... Cardboard still stays flat for some reason... IF you seal all the wood. Edges are most important.. But what do I know?
I also admit that I NEVER make a 'bunch' of evenly spaced Dog holes.. I make and fit for what I usually do over time. And then again, I DO like what the 'OLD Norm carpenter' did.. I cover it with tempered hardboard!
Every one has been marvelously restrained so I will drop t' bomb
Pray, tell how one flattens this bench top. I would have let it go and assumed one uses it only for power tool wood working and doesn't use it to flatten stock with a hand plane but there is a plane in the photo sooooo . . .
And lastly
Having a plywood bench top at home ( used for mechanic work )that I got splinters under my finger nails from until I covered it with another material. AND a plywood bench top at work ( used for mechanic work )that I got splinters under my finger nails from until I covered it with another material. I must question using plywood, especially cheep plywood , for a bench work surface for any kind of work.
(: )
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