Thread: Q: Benchtop material for lightweight general/mechanical workbench? + bonus Q's

Hi folks,

Been a while since I checked in here, was about to reply to one of my old threads but it says you can't do that after 730 days...

Anyway I'm planning out a lightweight workbench that will be used in my truck. Just for general & mechanical type work. No heavy thumping at all. The bench will be around 2,250mm long by 600mm deep. With 2 cross supports spaced evenly (about 700mm apart). Planning to build the bench out of 20mm SHS (1.6mm wall).

Now for the bench top I'm leaning towards either 1mm or 1.6mm steel sheet, and just painting it. I'm not too worried about it getting dents/gouges/etc. since I won't be thrashing it. Worst case the paint wears and I give it a fresh coat to jazz it up. The other reason I don't want a sacrificial layer is that there will be a sink installed, so I want to keep the (nearly) flush edge from the work surface to the sink.

The simple question is - would 1mm sheet be fine? Or can I go even less and save some weight/cost & still have a solid work surface? I just don't have any experience with this type of thing.

Bonus question: What would be the best/preferred method of mounting drawer slides to the 20mm SHS? The drawers won't be super heavy duty either, won't go higher than 60kg drawer slides. My first guess is to drill a pilot hole then use a thread cutting bolt? Or would it be better to use solid bar so I can tap a thread instead of relying on the 1.6mm wall thickness to hold a bolt?

Double bonus question: How would you construct the drawers themselves? I'm also just wondering about cladding/sides to the bench since there will be cupboards/shelves underneath, would something like 0.5mm sheet be ok? For the drawers I've been playing around with expanded/foamed PVC. Apparently this is used a lot in caravan/RV fitouts for benches, cupboards etc. It comes in sheets up to 25, 30mm thick and that stuff is pretty solid for how light it is. Waterproof as well so it won't be affected by the inevitable liquid spills. And easily joined with CA glue (superglue)... I played with some samples today and I'm a believer! But not the cheapest stuff, around $270 for a 2,440 x 1,220mm sheet. So any lower cost drawer options would be appreciated!

Cheers a bunch!