Ken Stevens
09-23-2007, 3:31 PM
I have been wanting to build this idea that I saw in one of the magazines several years ago. The dimensions result in a convenient way to get an assembly surface, 12, 24, or 36 inches high. The original idea, as I remember it, took ply sheets and cut out holes, but I did a layout and determined that I could get two boxes out of one 4x8 sheet rather than 2 sheets for the "hole cutout" approach.
These are simply 3 inch wide ripped strips that are cut into the proper lengths and screwed together with PH screws. They are plenty strong. One of the pics below shows where I clamped two together with some 2x2s. Very strong and stable. This would make an excellent large assembly surface. One of the pics show me using the first box to help assemble the second box.
While I expected these to be convenient, I was somewhat surprised unexpectedly at how convenient they were. Plenty of clamping surfaces, plus, it was easy to "pivot" the box around one of its corners, and it acted like it was on a turntable. Very easy to stay next to my bench where I could reach tools and screws, yet "get at" any angle for putting in the pocket screws.
Sharp eyes might notice that both boxes are not identical. When doing the first, I cut four of the final long elements too short and rather than throw them away, I altered the design to make short cross braces. I was more careful on the second box, and the original design (no short cross braces in the 12" sides) seems a little more desirable although both will work fine.
If I have any complaint, it is that they could be a little heavier. They seem very stable and certainly can support heavy loads. Wider strips or the cutout method would make them heavier but might require more than one 4x8 sheet per two boxes.
I will post a SU file showing the basic design using three methods: the cutout approach, using 2x4s, using 3" wide strips ripped from a 4x8 panel.
Ken
These are simply 3 inch wide ripped strips that are cut into the proper lengths and screwed together with PH screws. They are plenty strong. One of the pics below shows where I clamped two together with some 2x2s. Very strong and stable. This would make an excellent large assembly surface. One of the pics show me using the first box to help assemble the second box.
While I expected these to be convenient, I was somewhat surprised unexpectedly at how convenient they were. Plenty of clamping surfaces, plus, it was easy to "pivot" the box around one of its corners, and it acted like it was on a turntable. Very easy to stay next to my bench where I could reach tools and screws, yet "get at" any angle for putting in the pocket screws.
Sharp eyes might notice that both boxes are not identical. When doing the first, I cut four of the final long elements too short and rather than throw them away, I altered the design to make short cross braces. I was more careful on the second box, and the original design (no short cross braces in the 12" sides) seems a little more desirable although both will work fine.
If I have any complaint, it is that they could be a little heavier. They seem very stable and certainly can support heavy loads. Wider strips or the cutout method would make them heavier but might require more than one 4x8 sheet per two boxes.
I will post a SU file showing the basic design using three methods: the cutout approach, using 2x4s, using 3" wide strips ripped from a 4x8 panel.
Ken