I need some input on a utility bench design

[dan sherman]

I just started making 2 "utility" benches for my shop.

My design requirements where as follows:
1. Must be open underneath for role away tool storage.
2. Must be able to break it down for moving purposes
3. Must be able to handle a substantial load (as designed, it would probably hold up a small car).

What I came up with is as follows:

http://img262.imageshack.us/img262/9466/benchlm7.jpg (http://imageshack.us/)

Overall dimensions - W 72”, D 30”, H 40”– 44” (adjustable)

Top - 4” thick laminated hard maple. It should look pretty good when finished and provide a good base to mount my metal lathe to.

The legs & horizontal cross bracing are 2.5” x .12” square steel tubing

The rear diagonal bracing is 1-1/2” x 3/16” flat steel bar bolted to the legs. The theory is that since I have diagonals in both directions one is always under tension.

Right now I'm undecided on how to fasten the top to the base. I was thinking threaded brass inserts (3/8-16) in the top, and then drilling over sized bolt holes in the base to allow for expansion.

How much room do I need to allow for expansion?

[Dewey Torres]

Right now I'm undecided on how to fasten the top to the base. I was thinking threaded brass inserts (3/8-16) in the top, and then drilling over sized bolt holes in the base to allow for expansion.

How much room do I need to allow for expansion?

That top as laminated in your pic will not expand side to side to a noticeable degree.

Expansion and contraction happens mostly across the grain. You could just use lag screws in a slightly over sized hole. If the lag screw threads fit through the hole, that should be all you need.

I am not sure if you are dead set on building this but take a look at these options:

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=94309

http://www.samsclub.com/shopping/navigate.do?dest=5&item=329601

[dan sherman]

Already cutting the tubing to size. :D

I have seen both of these actually, the Sam's club top is decent, but both the bases are made of thinner sheet than I feel comfortable with.



I am not sure if you are dead set on building this but take a look at these options:

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=94309

http://www.samsclub.com/shopping/navigate.do?dest=5&item=329601

[Dewey Torres]

Alright Dan!
Good luck. post some pics when you get r' done.