Ken Frohnert
12-17-2008, 6:46 AM
Okay, I started cutting the SYP for the 24 Hour Workbench that was in Popular Woodworking a few years ago. I am making a few customizations - basically made it 7 foot long and moved the front legs to the edge of the top so they are flush with the edge. Anyway cut the tenons on table and band saw. On saturday I am going to finish cutting the mortises and try to get the base assembled.
For the top I am using 2 layers of basic 3/4" plywood that I have in stock, 2 layers of 3/4" MDF and then will lay a 1/4" piece of tempered hardboard on top which I can change if it get damaged. Once I had the 2 layers of ply and MFD together I was thinking of setting the top on the base and drilling 1/2 or 3/4" holes down thru the top and about 2" into the legs using the old brace and bit. Once I had the holes drilled I was going to pull the top off and put 1/2 or 3/4" dowels down into the legs and glue them in place. Then sit the top back on - hopefully the dowels will slip easily into the holes drilled earlier. I am somewhat worried about the dowels sliding into the holes in the top. Then cut and sand the down flush with the top of the MDF. Then sit the hard board on top to cover the MDF and the top of the dowels. My dad always practical suggested just sitting the top on and counter sinking heavy wood screws into the MDF and down into the legs (of course they would need to be atleast 4" screws) then sitting the hardboard on top to cover them.
There is probably a better method than either of these and I would appreciate your thoughts or advice. Thanks.
For the top I am using 2 layers of basic 3/4" plywood that I have in stock, 2 layers of 3/4" MDF and then will lay a 1/4" piece of tempered hardboard on top which I can change if it get damaged. Once I had the 2 layers of ply and MFD together I was thinking of setting the top on the base and drilling 1/2 or 3/4" holes down thru the top and about 2" into the legs using the old brace and bit. Once I had the holes drilled I was going to pull the top off and put 1/2 or 3/4" dowels down into the legs and glue them in place. Then sit the top back on - hopefully the dowels will slip easily into the holes drilled earlier. I am somewhat worried about the dowels sliding into the holes in the top. Then cut and sand the down flush with the top of the MDF. Then sit the hard board on top to cover the MDF and the top of the dowels. My dad always practical suggested just sitting the top on and counter sinking heavy wood screws into the MDF and down into the legs (of course they would need to be atleast 4" screws) then sitting the hardboard on top to cover them.
There is probably a better method than either of these and I would appreciate your thoughts or advice. Thanks.