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First, sorry for the long post. Its mainly a brain dump on my current dilemma, it helps to write it down.
Building some picture frames last week brought back into focus how NOT having a good assembley table is a real PITA. I have 3 main surfaces I use but none are perfectly flat or big enough for larger projects. As most of you know my shop has to do double duty as a functioning garage so I cant have a heavy permanent table or bench in the middle where it needs to be
My main bench is the biggest (6' x 32") and flatest (not perfect) but it is fixed in the corner of the shop and I cant get around all sides. My small bench (normally has my CMS station on it) is on wheels and has levelers so moves out when needed but its only 5' x 22". The main surface I tend to use is and old hollow core door edged with solid wood which sits on saw horses (5' x 32") - youve probably seen it in many of my pics. When I have needed a wider surface I bring the small bench and saw horse top together but requires all sorts of shims to get them vaguly the same height and then still nowhere near perfectley level or FLAT!
I have re-read all the assy table threads and most relate to some kick A$$ fixtures that I am jealous of but just dont have the room for. First I was wondering what size everybodies assembly tables are? I know from experience that 32" is too small for many projects 4' would seem ideal and of course match the width of sheet goods.
I am trying to figure out how to solve the issue and get a workable solution. Here are options that I am currently considering.
1. Rebuild a new top on my small bench or build a completely new bench. As it must live on the edge of the garage (even though it moves) the top would still be limited to about 25" - 30" wide.
2. Build a new torsion box top to sit on the saw horses 4'x5' min. As most designs I see are made from a combination of 1/2" and 3/4" MDF 3" thick this is going to be really heavy to move about on a regular basis.
3. try a multi beam construction (used with saw horses) as was outlined in a recent FWW article. It uses two torsion box beams approx 9" wide. You can use them on their own, or set them together (18") or apart up to the width of your saw horses. This still requires some tricky leveling issues when they are used together, the article doesnt mention it but it would seem to require a nice level/flat floor to work - my garage floor isnt either. If you can access FWW online here is the article.
Some questions I am considering:
1. How heavy is a 4'x5' 3" thick MDF torsion box? How would I move it?
2. How thin could I make it and still maintain the needed flatness?
3. Other material or construction options
In summary all ideas and suggestions the "collective" may have would be very much appreciated.
Building some picture frames last week brought back into focus how NOT having a good assembley table is a real PITA. I have 3 main surfaces I use but none are perfectly flat or big enough for larger projects. As most of you know my shop has to do double duty as a functioning garage so I cant have a heavy permanent table or bench in the middle where it needs to be
My main bench is the biggest (6' x 32") and flatest (not perfect) but it is fixed in the corner of the shop and I cant get around all sides. My small bench (normally has my CMS station on it) is on wheels and has levelers so moves out when needed but its only 5' x 22". The main surface I tend to use is and old hollow core door edged with solid wood which sits on saw horses (5' x 32") - youve probably seen it in many of my pics. When I have needed a wider surface I bring the small bench and saw horse top together but requires all sorts of shims to get them vaguly the same height and then still nowhere near perfectley level or FLAT!
I have re-read all the assy table threads and most relate to some kick A$$ fixtures that I am jealous of but just dont have the room for. First I was wondering what size everybodies assembly tables are? I know from experience that 32" is too small for many projects 4' would seem ideal and of course match the width of sheet goods.
I am trying to figure out how to solve the issue and get a workable solution. Here are options that I am currently considering.
1. Rebuild a new top on my small bench or build a completely new bench. As it must live on the edge of the garage (even though it moves) the top would still be limited to about 25" - 30" wide.
2. Build a new torsion box top to sit on the saw horses 4'x5' min. As most designs I see are made from a combination of 1/2" and 3/4" MDF 3" thick this is going to be really heavy to move about on a regular basis.
3. try a multi beam construction (used with saw horses) as was outlined in a recent FWW article. It uses two torsion box beams approx 9" wide. You can use them on their own, or set them together (18") or apart up to the width of your saw horses. This still requires some tricky leveling issues when they are used together, the article doesnt mention it but it would seem to require a nice level/flat floor to work - my garage floor isnt either. If you can access FWW online here is the article.
Some questions I am considering:
1. How heavy is a 4'x5' 3" thick MDF torsion box? How would I move it?
2. How thin could I make it and still maintain the needed flatness?
3. Other material or construction options
In summary all ideas and suggestions the "collective" may have would be very much appreciated.
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