Thread: Solid-Core Door Workbench - WIP

Having a nice solid workbench with a good vise on it will be a great addition to your workshop Steve. You will wonder how you did anything without it .

Bret

Originally Posted by Hermit

Not bad looking, Bret. Pretty solid and definitely better looking than mine will turn out, but mine will be equally solid, I hope, with 3 1/2" square legs and frame.
I won't need to add weight, either - moving it will be the problem: - the base is about 22 metres of hardwood 4 x 2's, and when that's added to the weight of an 80" x 36" x 1 1/4" solid-core door, along with a top protective sheet of plywood and my large vise, it won't be going anywhere as I work.

You are right Hermit. I don't think you'll have any issue with your bench being too light. The legs and the top rails on mine are 4x4 oregon, not hard wood like you are using and it is heavy enough. It doesn't move.
The plywood would be nicer for a layer on top of the door rather than the laminated particle board i have. When I made mine, the local bunnings store was in the habit of dumping a lot of useable things in a skip bin and anyone was aloud to help themselves, so I did . Due to OH&S (or WH&S dependant on where you live) this doesn't happen anymore.

The screws arrived yesterday. I've been flat-out on other things, but at least made a start tonight and screwed/glued-up the first join. Getting a bit too cool out there to continue right now.

I'll buy the remainder of the 4 x 2's and some plywood for a sacrificial top and the shelf too if I have enough $, tomorrow.

I still need a bit more hardware, bolts etc, but I'll make a short list and organise that over the next couple of days too.

Edit: I just realised. This pic shows why I want a good 100mm overhang on all sides. More clamping room.

All systems go.....

I finished the first base end-frame today. Also have the next lot of timber arriving on Monday. I got another 4 x 3.6m of 4 x 2's, but didn't get the plywood yet. $$$. The 4 x 2's cost $209 delivered, same as the first 3 and the door, so the timber total so far is $418.
This thing sure is going to be heavy - already an effort to lift.

Both base end-frames are finished: -
Attachment 213115


and the new load of timber arrived yesterday, for the 4 main rails, (8 x 4' 4x2s laminated): -
Attachment 213116


Also, I decided that if I'm spending this much on timber, I should dignify it with a new vice, rather than the crappy old one I planned to use, so I bought a Groz 225mm, 330 mm opening, from Carbatec. Not a quick release, I didn't want to push my luck too far with Groz.
Groz aren't top shelf, but not a bad vice on inspection and infinitely better than the old one: -
Attachment 213117
Attachment 213118


I'll knock up the rails over the next few days.
Getting there.

Progressing nicely.

Looking good Steve

You are going to love the vise. Especially for your toy making




Bret

Originally Posted by bj383ss

Looking good Steve

You are going to love the vise. Especially for your toy making

Bret

Yeah, after working with only a 4" vice or my clamp bench for 4 months, a real woodworking vice attached to a solid bench will be a real luxury. I can't wait.
I'll knock the rails over pretty quickly, then it's just the 3/4" plywood for the top sacrificial layer and the shelf before final assembly.

Somehow, I'll have to try to stretch the budget and get the plywood this week, I think, rather than wait for payday next week. Maybe borrow a little more from my savings. (Shouldn't really have even bought the vice.)

I don't even have any idea what 3/4" plywood costs, yet. I'll need one 2400mm x 1200mm sheet for the top and the better part of a second for the shelf and shelf cleats and for a 30mm spacer for the vice, to make the benchtop up to 80mm so the top of the vice is level.

Steve

In my neck of the woods a sheet of 3/4" ply ac is about $30. A good cabinet grade one is $50

Bret

Originally Posted by bj383ss

Steve

In my neck of the woods a sheet of 3/4" ply ac is about $30. A good cabinet grade one is $50

Bret

That's not too bad. After paying $13.50/metre for the 4 x 2's, $368 total, + $50 for the door, I wasn't sure what to expect. Our prices are probably a little different, but it's an idea at least.
I'd probably get one cabinet-grade sheet for the top and a rougher one for the shelf etc.
Better get off my behind and get some bolts to connect the rails to the end-frames, too. I've been buying on a 'just-in-time' basis.

I finished laminating the 4 rails today, so I only need to square off the ends of the rails a little, make up the pocket-hole joints and then bolt the base together.
Edit: The rails are a little over 4 feet long - 1300mm.
Attachment 213278


Also ordered the 3/4" plywood and a few metres of 42mm x 19mm for the shelf cleats.
I couldn't get 'cabinet-grade' plywood, so got 2 sheets of 'structural grade'. I'll give it a sand and it'll be fine for a benchtop. If it's a bit rough, I'll give it a coat or two of poly.
The ply etc will arrive first thing in the morning.

Bret, it's a little more expensive here than in the US - the (2400mm x 1200mm) sheets of 'structural grade' cost $62.25 each. Pretty hot, I thought, but that's life.

Today's total was $140 delivered, bringing the total cost up to $668 so far. (That includes $110 for the 9" vice.) Today's stuff actually came to $146, but I only had $145 in my pocket, so he gave me a discount and made it $140. (Home Hardware)
Trouble is, I didn't have anything left for the bolts to assemble the base, so I can just get everything ready for now, then maybe borrow more from savings tomorrow to finish off over the weekend. I'll see what happens.

Originally Posted by Hermit

I finished laminating the 4 rails today, so I only need to square off the ends of the rails a little, make up the pocket-hole joints and then bolt the base together.
Attachment 213278


Also ordered the 3/4" plywood and a few metres of 42mm x 19mm for the shelf cleats.
I couldn't get 'cabinet-grade' plywood, so got 2 sheets of 'structural grade'. I'll give it a sand and it'll be fine for a benchtop. If it's a bit rough, I'll give it a coat or two of poly.
The ply etc will arrive first thing in the morning.

Bret, it's a little more expensive here than in the US - the (2400mm x 1200mm) sheets of 'structural grade' cost $62.25 each. Pretty hot, I thought, but that's life.

Today's total was $140 delivered, bringing the total cost up to $668 so far. (That includes $110 for the 9" vice.) Today's stuff actually came to $146, but I only had $145 in my pocket, so he gave me a discount and made it $140. (Home Hardware)
Trouble is, I didn't have anything left for the bolts to assemble the base, so I can just get everything ready for now, then maybe borrow more from savings tomorrow to finish off over the weekend. I'll see what happens.

G'Day Steve,
$62 is pretty good for 3/4" ply, I thought you'd be paying closer to $80.
So good the prices for woodwork stuff in the USA.
Your bench is really taking shape.
It'll nearly need a forklift to move it around the shed once finished.
Keep up the good work.
Cheers, crowie

Originally Posted by crowie

G'Day Steve,
$62 is pretty good for 3/4" ply, I thought you'd be paying closer to $80.
So good the prices for woodwork stuff in the USA.

Right. I had no idea what prices to expect here. Not really whinging - it'll be worth it in the end, and I see that to buy one this solid would have cost at least double what I'm paying.

Your bench is really taking shape.
It'll nearly need a forklift to move it around the shed once finished.
Keep up the good work.
Cheers, crowie

You're not wrong. Just the bits are heavy to move around now and I can barely move the door by myself. (I dragged it in when it was delivered.)
I've already lined up help for the heavier stuff, like turning the assembled frame upside down on the door to attach it, then getting it upright again with the added weight of the solid-core door. There are 3 of us, but I might need a fourth for that bit. I'll attach the plywood when it's upright again.

When it's done, I might need a couple of trolley jacks to get it into place.

Originally Posted by Hermit

Right. I had no idea what prices to expect here. Not really whinging - it'll be worth it in the end, and I see that to buy one this solid would have cost at least double what I'm paying.




You're not wrong. Just the bits are heavy to move around now and I can barely move the door by myself. (I dragged it in when it was delivered.)
I've already lined up help for the heavier stuff, like turning the assembled frame upside down on the door to attach it, then getting it upright again with the added weight of the solid-core door. There are 3 of us, but I might need a fourth for that bit. I'll attach the plywood when it's upright again.

When it's done, I might need a couple of trolley jacks to get it into place.

G'Day Steve,
Do you have an "ENGINEERING PLASTICS" company down the south coast; something like Dotmar in Sydney.. http://www.dotmar.com.au/ .
You could get an offcut of self lubricated nylon, i can't remember the correct name; but the tipper trucking industry use it on the guide runners for their load covers.
The material could be fixed with countersunk screws to the legs allowing you to slide the bench.
Should / Could help.
Cheers, crowie