Replies

1. 
   warden314 | May 31, 2022 05:12pm | #1

   The Wood Whisperer did a very nice video on this many years back. Basically use some saw horses, 2x4's, shims and plywood and some winding sticks to get to an initial flat surface and build from there.

   https://www.youtube.com/watch?v=1-Hbsou6cWo&ab_channel=TheWoodWhisperer

2. 
   Badger1805 | May 31, 2022 05:13pm | #2

   Why not build a 54" x 24" torsion box? If the pieces/joinery are milled and assembled accurately, it should go together to create a fairly flat surface. If for some reason there are any high spots, you could use winding sticks and a hand plane to correct them.

3. 
   rob_ss | Jun 01, 2022 04:04am | #3

   Seconding the suggestions for a torsion box.
   I made a near full-sheet sized version of the Wood Whisperer table. Made the mistake of using cheap ply which was very difficult to get flat but ended up close enough.
   A good overhang on all sides allows for very effective clamping of laminated glue-ups. I have made a set of garage doors and a queen sized bed on it!
   TBH it's a little bigger than I would like, but the two big projects needed it and then some. It's on castors so it can be moved out of the way a bit.

4. 
   stantheman | Jun 01, 2022 08:13am | #4

   Kitchen counter material. You can get leftover pieces from installers, habitat restore, or sometimes the big box stores will have them for cheap. No assembly just cutting to size.

5. 
   bilyo | Jun 01, 2022 10:31am | #5

   A solid core door makes a good flat workbench top. You can often find used ones. Put a piece of Masonite on it if you need a smoother surface.

6. 
   fourier_transform | Jun 01, 2022 02:33pm | #6

   David Marks shows how to build a torsion box assembly on his TV show Wood Works. I built mine using MDF in 2004 and it is still going strong. Dead flat--always has been.

   However, it is not light. It will take a couple of burly guys (or gals) to get haul it out of the basement if you ever move.

1. 
   EdWeber | Jun 02, 2022 02:17pm | #8

   https://vimeo.com/5082731

2. 
   stevieray | Jun 03, 2022 03:38am | #9

   The David Marks video is worth watching. He shows how to get a fiat reference surface on sawhorses, and then how to build the torsion box. I always wanted such an assembly table but make do with my workbench. Note that good workbenches can be flattened with a long hand plane. I use a number five every few years, and it ends up dead flat.

7. 
   elmaduro | Jun 02, 2022 08:24am | #7

   +1 on the solid core door. At 80lbs, it makes an instant dead-flat workbench top.