Question regarding ply laminate for workbench top
A “Q & A” Topic on FWW talks about using 3 layers of 3/4 baltic birch ply as a workbench top, citng the importance of using the birch ply for its void-free construction.
While reading Landis’ “Workbench Book,” he talks of a cabinet-maker in the NW who build his workbench top by laminating 3.5″ strips of 3/4 ply sandwiched between two layers of tempered hardboard, providing a strong, flat, and stable surface. The grade of ply (void-free furniture vs construction) used was not indicated.
My question is: with the 3.5″ wide strips of ply being laminated on end, similar to the “butcher block” laminations used for commercially available hardwood benches, would it be acceptable to use standard “home center” 3/4 ply instead of expensive void-free baltic birch? I am pondering and planning a workbench build, but (not to beat a dead horse) have some budgetary restrictions. I am trying to find a good balance of cost and quality. Since, hard maple (or really any domestic hardwoods suitable for building a large, thich bench top) is not native to the Arizona desert, the lumber cost is significantly higher than prices in the East and Midwest (upwards of $7/bf for clear, quality lumber). I am considering laminating two doghole strips from 8/4 hard maple, to be glued to either side of a plywood-laminated top (also, considering a center strip of maple for holdfast holes). In my mind, that provides the strength of the solid maple on the sides – where the bench dogs will be located as well as where the majority of clamping, hammering, chiseling, and sawing takes place – with the stability and cost efficiency of plywood for the bulk of the top. This would allow me build a thick, stable bench-top for $500-$700 less than if I built the entire top from solid maple, without spending a few hundred dollars on something I will immediately want to replace…which is exactly what will happen if I just build the standard “El Cheapo” plywood workbench or “Two-by-” bench using construction grade Douglas Fir.
Replies
I built a workbench top similar to this is 1997 or 1998, and it has worked out very well. I used laminated veneer lumber (LVL) as a raw material. It is similar to plywood, but the grain in all the plies runs the same way. It is used for structural headers in construction. The 24" wide top is 1 3/4" thick and is about 200 plies wide of 1/8" doug fir veneer.
I'd say the veneer in the LVL material I used was a B grade with knots and voids up to 1". For comparison, the core plies in unsanded sheathing plywood will have D grade veneer with voids up to 3" and sanded flooring plywood will have C grade veneer with voids to 1 1/2".
The plywood you want to use will be less stiff end to end since half the plies will be cross grain, so you would probably need the extra thickness to keep it straight.
Expect considerable widthwise expansion and contraction and support the top accordingly. I would not try to glue faces to the top and bottom surfaces to avoid cupping.
I tries to post a photo, but the spam filter wouldn't let me.
Find someone with an abrasive planer to surface it. The glue lines really beat up knives.
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