Torsion Box Questions

[LarryG]

I built my torsion box assembly table using essentially the same method as Keith, except I used 1/2" MDF for everything except the outer bands of the cells, which are 3/4" MDF (which are in turned capped by 1/2" red oak).

My table measures 42" x 60"; I would suggest you make it as large as you reasonably can. The dimensions of mine mean I could not get both skins out of a single sheet of 1/2" MDF, but for something that will be such a major addition to one's shop, the extra fifteen bucks or so for a second sheet is peanuts.

If floor space is tight, consider putting the table top down at about the 18" level, as I did. This allows you to make the table a little bigger than if it were at normal height and still move around it without too much trouble; the lower the table is, the smaller and more out of the way it will "feel."

Lastly, if you plan to assemble the inner cells with an air nailer, be double-sure to make the cells big enough to get the gun into them so you can shoot the toenails. I miscalculated and got my cells about a half-inch too small, and assembly was a major pain.

[mcgrath4u]

We had a warm spell here in Michigan so I started on building the torsion table.

I took the same steps that drumpriest and larry took. Last thing I did was to glue and nail the bottom skin on.

Its cold here now, I may have to stay inside and wait to finish filling holes and sanding and flushing.

John

BTW, did you guys have problems toe-nailing the mdf with a brad gun?

[drumpriest]

Well, I glued it all up, and toenailled. The mdf tends to split out, but it's not a big issue. When you add the top and bottom, if you are liberal with the glue, the glue will fill up most of the gaps. Remember the MDF is nothing but glue and dust compressed.

[atgcpaul]

My WWing teacher gave us a tour of his shop where he makes
cabinets for a living. He had the most incredible torsion
box assembly table I have ever seen. He used 2 massive
MDF sheets for the top and bottom (something like 8x12),
with 4"x4" ribs spaced internally. To make this dead flat,
he set up a system of shims and used a floating laser level
to make all the shims level. Then he layed on the first
piece of MDF and built up from there. To clamp the whole
thing up, he drilled a vacuum port on the side apron, and
used a vacuum pump to suck everything down.

He put plastic laminate on top with a solid maple edge
overhang to allow clamping down to the table. Very nice.

This massive setup sits on a hydraulic lift that can lower
the table to 1' off the ground and raise it up nearly 4'.
He can now move whole carcasses and assemblies right onto
the table at close to floor level, and raise it to a
comfortable height for assembly, finishing, whatever.

If he had the sponsorship, I'm sure he'd put Norm to shame
on tool ownership. This man likes his gadgets. In his
words, "Using cheap tools gives me a rash."