Brand new guy here.
I've been primarily a model builder for many, many years, but have also done several larger "real" wood working projects. The big constraint has been space. I usually have to do the work out in the garage, preferably either with the door open or in the driveway for dust control. Being Minnesota, that limits me to about 6 mos. of the year. "Job site" type table saw on folding stand, miter saw, mid-size router (no table). When needed, my "bench" for those projects has been a partial sheet of ply on saw horses. Smallish basement room for the modeling workshop, with a 12" bandsaw, benchtop drill press. Currently in there is a 40"x88" bench ('tis as big as would fit in the space!) consisting of 2x4's cleated to a wall, with the long rails out into the middle of the room with legs at the ends. The top is two pieces of 1/2" ply. I've contemplated converting it to a torsion box style top for a long time, but never got around to it - a dead flat surface would be a huge boon to the modeling.
A broken pipe in my exterior wall and the associated insurance/contractor brouhaha has got us seriously thinking about replacing a very old basement wet bar, and on the other side of the wall, upgrading the laundry room.
Which means cabinets.
That would be new, but it seems within my abilities.
But now it is time to get serious about a bench.
I find the current indoor bench size just about ideal for my general uses. So am thinking about making the torsion box the same dimensions. I would remove the current ply tops, and just use the existing frame to support the box, but not fasten it in place. When the need arises, I would then like to lug it upstairs to the garage for the once-in-a-while bigger projects, supporting it on saw horses.
I've seen the Wood Whisperer videos, and seen most of the posts here about building one. While MDF sounds easiest/cheapest, the overall weight seems to be the killer - it could be up to 200-250 lbs! I also saw the videos for the "Paulk" portable bench. While along the lines of what I'd want, it doesn't seem to be a "true" torsion box - meaning it may not be as dead flat and rigid as it might otherwise be. So, I'm contemplating a hybrid - 1/2" birch ply for everything, following mostly the WW ideas - with lightening holes in the interior braces.
The other stumbling block is the base to build it on - the video assumes I've got access to a jointer/planer to run 2x4's through (which are used with saw horses, levels and winding sticks to serve as a flat base to build on top of)...which I don't.
So, the priorities:
Very rigid and flat. Will stay that way, even when well supported only near the ends for long periods (meaning my current bench rails sag a bit currently!)
"luggable" by one, or perhaps two (if I can talk my wife into helping).
Comments, links, tips, and suggestions for the design and construction are all appreciated!
Ted