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  1. #1
    Join Date
    May 2010
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    Default Not so quick but Easy Bench WIP

    Hi All,

    Well after some extended planning last year and a bit of time Off I've finally managed to start making some progress on my very first bench build. I've modeled the base off the internet plans for the workbench 1.0 which is basically just a torsion box of 90x45 construction pine and 15mm plywood bolted together.

    Having gotten this base bolted together It certainly feels rock solid and has a fair heft to it, to the point that it is now officially in the difficult to move it by myself.

    With this done i am departing from the plans when it comes to the workbench top. My current plan is to make a 4 layer lamination of 16mm mdf plus a 6mm sacrificial masonite top for a 70mm thick bench edged in pine. I'll be adding a single bench construction vice to the left hand side of the bench front.

    My plan for laminating the MDF is to very lightly sand with 80 grit paper, clean and then glue all layers together with white PVA glue spread out with a grooved squegee. I only have 4 30cm quick grip clamps to hold this together.

    So my question to all of you knowledgable folk out there is this. Will the white PVA glue be sufficient for the task? and if the MDF is left with the glue drying just under it's own weight, will this provide sufficient strength for a bench top if left overnight?

    I'll post up a few photos of the base when I get a chance.

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  3. #2
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    Default

    Not sure I can help much with some of your questions

    But I'd be inclined to glue and screw

    ie two pieces of mdf glue as you suggest then drive sone screws in a pattern to pull it together. keep flat. when dry remove screws and reuse when glueing on the next layer,
    regards
    Nick
    veni, vidi,
    tornavi
    Without wood it's just ...

  4. #3
    Join Date
    Dec 2008
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    Bradbury
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    Default

    I would definately screw it as well. It'll help pull it all together

  5. #4
    Join Date
    May 2010
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    Sydney
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    Default

    finally some progress. i've managed to glue up the,4 mdf panels for the workbench top. what I did find is that when trying to screw the panels together it seemed to actually seperate the pieces rather than bring them together. as such I scratched that plan and just clamped it down as bes I could and I seem to have an accaptable result.

    I cleaned up the edges with a cicular saw, it took 3 goes but I finally worked out the trick to making sure the cut is square to the top, avoid putting to much weight on the saw. unfortunately this does mean that the back is not completly square but the front and sides are. I can live with that.

    only 4 things left to do now
    - glue on the pine edging
    - bolt the top down with some lag bolts
    - add a sacrificial layer of masonite
    - add on the vice.

    I've attached a pic of what things look like now complete with the old desk i've been using to build the workbench.

  6. #5
    Join Date
    Feb 2006
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    Perth
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    Default

    Quote Originally Posted by Mr Big View Post
    finally some progress. i've managed to glue up the,4 mdf panels for the workbench top. what I did find is that when trying to screw the panels together it seemed to actually seperate the pieces rather than bring them together.
    When drilling the holes, before screwing the sheets together it's worth separting the two sheets and lightly counter sinking both sides of the holes between the pieces. This clears any sawdust and fibres that are forced into the gap by the drill and enables the screw to grab and hold the second sheet cleanly.

  7. #6
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    Perth
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    Default

    Quote Originally Posted by BobL View Post
    When drilling the holes, before screwing the sheets together it's worth separting the two sheets and lightly counter sinking both sides of the holes between the pieces. This clears any sawdust and fibres that are forced into the gap by the drill and enables the screw to grab and hold the second sheet cleanly.

    A habit that everyone should develop and employ when gluing and screwing and joining any pieces of timber, chipboard and or plywood together. It will makes a big difference in achieving hair line joints.
    Malcolm Eaton

  8. #7
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    Default

    Quote Originally Posted by Mr Big View Post
    what I did find is that when trying to screw the panels together it seemed to actually seperate the pieces rather than bring them together. as such I scratched that plan and just clamped it down as bes I could and I seem to have an accaptable result.
    Did you pre-drill the holes? MDF has a habit of swelling when not pre-drilled.....

    To glue/screw two sheets together, I'd clamp them together first all lined up, then drill through both layers with a bit the correct size for the screw. Then separate them, clean out the drillings, then for the top sheet only, enlarge the holes so the screw only bites in the lower layer. Then apply glue and screw them together, guaranteed not to separate..... Doesn't take much longer either....

  9. #8
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    FenceFurniture is offline The prize lies beneath - hidden in full view
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    Without knowing what sort of screws you used, if they were long threads they'll give great difficulties unless the panels are clamped together before screwing.

    Plus what the others said about cleaning up the holes.
    Regards, FenceFurniture

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  10. #9
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    I was just using some 30mm phillips head wood screws. I didn't have the holes pre drilled, so this is likely ehere the problem was as I just clamped up the edges and then started on the screws.

    Live and learn I guess. Well hopefully I'll get some time this weekend to get the edging on and go from there. I'll be going for some basic singledovetails at the corners as I think this will work better than a mitre joint give that the back is not 100% square.

  11. #10
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    Well just a quick update, Easter being Easter, about all I got time for was to cut the edging to length, but I suppose thats progress at least. I'm Also thinking that I'll need to get some edging clamps before I can finish the glue up as I want to avoid using screws on the external face.

    I guess a trip to carbatec is in order to pick up some more clamps.

  12. #11
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    Mate

    Like everyone else I would definatley glue and screw the MDF together. If you go to my bench build I just modified an assembly table into a bench to work on my new bench and I used two sheets of MDF as the top.

    A couple of things:

    I used Shelley's White PVA for the glue.....I had a bottle laying around, it should be fine. Saying that Masters has the huge bottle of Tightbond 3 for $39.....Oh my hat...I snuffled up a bottle quick sharp! 3 or 4 litres I think!

    • Lay out a grid and drill and countersink the bottom sheet.
    • flip it over and give the holes a very quick whip with the countersink to clear the gnurls.
    • then spread the glue, align, use your quick grips to keep in place and screw away! Start in the middle and work your way back out to the edge.
    • I just used blue tape as clamps for the edge banding but got inpatient so I whacked in a few screws to speed things up.

    Your design should make a rock solid workbench!

  13. #12
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    so next step here, due to laziness combined with a desire to actually make some progress i've staryed glueing on the edging using a trick I picked up on the net to avoid buying real edge clamps.

    the attached photo should give you an idea.

  14. #13
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    As long as it holds with some pressure it's a good idea.

  15. #14
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    Well finally there has been more progress. i've managed to add the final layer of masonite to the bench top, i've also drilled through the holes for the bench vice.
    so at the moment i'm glueing up the final pieces for the vice ready to glue on, then it will be some final prep and finishing then assembly.

    i've also got a progress pic of the bench and vice hardware.

  16. #15
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    I like that wedge system you've used there to clamp the end on. I've not seen that before. So simple.

    Great work!
    ...I'll just make the other bits smaller.

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