Flattening a laminated workbench top suggestions.

[goslin23]

I live in a growing neighborhood with new construction going up all the time. I asked the construction supervisor what was done with the scraps.. he told me to take whatever I wanted but make sure they were scraps!

Scraps to these guys are full length dimensional lumber that they've used to brace walls and such as they're building these houses. I grabbed as many 2x4's as I could get my hands on and cut off the parts with nails. I jointed and ripped them to 1 1/2" x 3", glued them as flush as I could and built a workbench out of them.

My next step is to flatten the top and I need your suggestions on how you would go about this task. Hand plane, router setup, a whole bunch of sanding or any other suggestion that you have outside of a surface planer (the top is 48" long x 30" deep).

-=gos=-

[JR]

I'd use a router.

Tack a couple of 1-by rails to the front and back, making sure the tops are level and coplanar. Build a bridge for the router to ride in. Fly a fat straight bit and just mow it down, moving the bridge along the rails.

JR

[bthere]

A hand plane would give you a nice work out and allow you to practice sharpening. I think you might be able to do it with a belt sander if you are much more skilled than I am using one.

However, a flattening jig that uses a router would work pretty well. I used a similar setup to this for an old work table that was fabricated from 2x lumber. It only requires a little work to finish sand once you are through with the router.

[Scottydont]

I built a flattening jig like Bthere recommended. I used a scraper and palm sanded the rest of the way.

[goslin23]

Thanks for the replies, I was leaning towards the router technique and wanted to make sure that it was the way to go. now I just have to pick up a fat straight bit, the only one I have is 3/8".

[Garasaki]

I'd seriously consider going to a local cabinet shop and asking to use their drum sander.

probably would cost 50 bucks, but lord it'd be so much easier.

[goslin23]

I'd seriously consider going to a local cabinet shop and asking to use their drum sander.

probably would cost 50 bucks, but lord it'd be so much easier.

That was a consideration. But given the fact that I have all of about $5.00 (lag bolts & washers and a some glue) plus labor into the whole bench, I figure I would like to finish it on my own. Plus, I really didn't need a workbench right now, so it was just something to do in the garage on the weekend until I save some $$ to build my other projects.

-=gos=-

[footprintsinconc]

i used the router technique myself when i flattened my maple top for my work bench. infact the pictures are in the gallery, under footprintsinconc.

the rails and the sled were scrap 2x4s that i flattened and surfaced before i used it. i used a 3/4" bit on the router. i did the top in two passes because to top of my rails were were just under an 1/8" fromt the top, so the shavings were actually lifting the sled by like 1/16" in spots. at the end i used an orbital sander (5" dia) starting at 100, then 150 and then 220 grid paper.

lets see if i can post them here: (good luck!)

[goslin23]

i used the router technique myself when i flattened my maple top for my work bench. infact the pictures are in the gallery, under footprintsinconc.

the rails and the sled were scrap 2x4s that i flattened and surfaced before i used it. i used a 3/4" bit on the router. i did the top in two passes because to top of my rails were were just under an 1/8" fromt the top, so the shavings were actually lifting the sled by like 1/16" in spots. at the end i used an orbital sander (5" dia) starting at 100, then 150 and then 220 grid paper.

lets see if i can post them here: (good luck!)

That's exactly what I was looking for..

thanks!