Building a New Assembly Table

[DWyatt]

Finally making some progress on the new shop. The next line of business is building a new assembly table. I've always worked in my Dad's shop and I dread working around the assembly table. It's very small and a little too high for my liking.

Started with some 6/4 beach that I cut and dried a few years ago. It is rough, very rough. Used the circular saw to cut a straight edge on the boards then cut them into 2 1/2" strips. Face joint, plane, edge joint, then glue up into a butcher block style top. The goal is to have a 2 inch finished thickness. Here's some pictures from the progress so far, I just finished the second of 3 glue ups. Each section of the top will be 20" wide x 10' long, giving me a 5' x 10' table. The base will all be made of steel to keep everything flat. Once all of the pieces for the top are glued up, I'll run them through the planer then I have a lot of holes to fill with epoxy.

Strips cut and ready for milling


 

Successful glue up #2


 

Section #1 of the top. It's by for the roughest as far as knots in the wood.


 

[DWyatt]

For anyone has considered purchasing one of these glue bottle rollers and wondered if they're a gimmick. Please do yourself a favor and buy one. It no doubt was the reason I was able to glue up 16 boards without running out of open time with the glue. It was my first time using it and I feel dumb for avoiding the $8 expense for so long. 



 

[doc henderson]

I have a glue bot and a roller, I think I can swing the 8 bucks and give one a try based on your thoughts.  would not use it for everything, but great for bulk projects.  looks great.

[DWyatt]

Doc, I thought the same thing. $8 is worth a try. Probably not good for the majority of things I do, but I am going through just over a 16oz bottle of titebond for each of these three glue ups so open time is a real concern. This thing makes spreading glue so fast for laminating these boards. I think it was on sale at rockler and it comes with an 8oz  bottle, but the threads match the titebond bottles.

[doc henderson]

thanks.  I looked on the jungle shopping network (amazon) and they looked cheap and the roller did not have the groves, just smooth.  the groves make sure you leave enough glue on.  I like Rockler, but not cause they are cheap.  and the cheap ones are 13 bucks.  

[trimguy]

I used a cheap one when I did my bench top. I liked it when it worked, the glue bottle neck would crack and ooze out ( it was a 3 pack).  I have since bought the Rockler one one because I'm sure it's better quality and it fits the tite bond bottles. I haven't tried it yet.

[doc henderson]

got to the shop and found one I forgot I have.  a gift from my neighbor, but a smooth roller and a flimsy bottle. >:(

[Larry]

I suppose I've made more than 50 tops using the same method.  Reloading benches, dining tables, workbenches, fish cleaning stations, and more.  Great way to use up low grade.

This bench is one of my better ideas.  I found used file cabinets at bargain prices during the last recession.  I left a hole on the other side for a chair.  I've used it most every day for the past nine years and it shows it.  Time for a re-finish.



I've been using a cheap brayer (rubber roller) I got at maybe Hobby Lobby years ago to spread glue.  Works good nuff I'll not change.  Used it this morning for a natural edge table glue up.

[doc henderson]

some angle iron to cradle that all and some casters and you will have a heavy (depending on what is in the cabinets) rolling workbench/desk.   8)

[DWyatt]

Larry, I love the file cabinets under the work surface. I'm planning to use 6 ea square tube legs then c channel on edge for the perimeter and 2" square tube about 6" up from the floor. Planning to have c channel laid flat on the bottom of the wood top to keep things flat and held together. Probably not going to glue the three individual pieces together because it will be too heavy to move in the future. I'll eventually fill in with drawers/cabinets in between the legs. 

[DWyatt]

2 glue ups done, third one in the clamps. 55 ounces of glue used!



 



 

[tacks Y]

Nice job with the beech.

Do most of you that built benches put poly on them? Making one now for my wood shop with hard maple. I am thinking it would work nice wiping glue off and such, not worried about the looks.

[Larry]

I've always used Waterlox High Gloss for the finish on assembly workbenches.  When I do a glue up I just let the glue drip out and dry.  After its dry I take a 1" chisel and pop off all the drips.  They come off super easy....probably took 15 seconds to clean up the drips from this glue up.  I think any good poly will work well on a bench.


 

[DWyatt]

Finally had a minute to make some more progress. Last night I got the 3 pieces all planned down to a consistent thickness. I have to say, I am pleasantly surprised with how purdy this is going to be. I did not have my hope set to high with seeing how rough the tops were after glue up. Started digging out the loose knots and bark then sanding this evening. Progress is unfortunately slow, but progress none the less.

[DWyatt]

For some reason I'm getting an error when I try to add pictures, saying I don't have permission. I'll try from my computer in the morning. Leaving you hang until then

[thecfarm]

problem posting pictures

[DWyatt]

Chisels, a pick, wire wheel on the drill, and 80 grit sandpaper. I'm making progress. Seal coat of epoxy to take care of some of the soft areas scheduled for this weekend then filling knot holes 8)



 





 

 

[DWyatt]

Finished up sanding the last piece this evening and got everything seal coated on the top with epoxy. I used total boat penetrating epoxy for the seal coat. A few spots are a little spalted so I'm hoping they'll stiffen up. Pouring knot holes tomorrow and Sunday with total boat high performance epoxy. Real impressed with how this stuff looks.



 



 

[samandothers]

Your experience with the two different epoxies may be something to share on Doc's Epoxy thread.  Some insight on how well the penetrating epoxy worked on your punky wood and how they interact when over coating with a different version of the Total boat.

The top does look great!

[DWyatt]

@samandothers this is an experiment for me so I think I should wait until I make sure it doesn't all blow up :D

Had my first filling for the knot holes. Total boat high performance epoxy for this task. The one section of the top had A LOT of knot holes. Excited to see the results once I scrape it down! 



 

[DDW_OR]

also reclaimed bowling alley lanes

[beenthere]

For my workbench top, and also for a built-in entertainment center, I was able to buy a truck flooring product that was manufactured in 12" by 40' lengths of glued-up 7/8" oak strips.

Have a 12" cut-off piece remaining shown here. Boys had a school project and drilled out some holes for wood dowels that I cut off to use it as a "cutting" board.


 

And a shot of the cluttered-up workbench in the shop.


 

[DWyatt]

Made a little more progress last night. Just sanding, my least favorite part of projects. Then filled the little holes with epoxy that emerged as I sanded. Planning to have them cut to size and finished before building the base next weekend.





 



 

 

[DWyatt]

Another late night if sanding. Everything is sanded to 120 which is as far as I'm going. Just have to cut to length and kerf the joint so everything fits together nice then it's time for finish  8) The part I'm really struggling with is that I normally make furniture and I have to keep reminding myself that this is just a work bench. The woodworker in me wants to spend 10 hours chasing pin holes in the epoxy. Dad reminds me that I'm over the top and just need to get it done.



 

[Walnut Beast]

It will be worth it 👍

[Andries]

That top doesn't look like scraps and left-overs anymore. 😊 

[tacks Y]

Very nice, I wish mine was that size.

[samandothers]

Bunch of labor in the deck top, Whatta a work bench!  Great looking so far.

[Tom K]

Great looking top! After you use it for a year or two and get a little wear and tear on it you won't even notice those pin hole you didn't fill.

I'm looking forward to seeing the whole project when done. I decided to go with several smaller (3'x7'ish) movable work benches for my shop. I have a bad habit of covering every flat surface with "stuff", so with a couple smaller ones I can just push everything onto one bench so I can use the other  

[DWyatt]

That is part of why I made this thing so big. I should be able to push everything to one side and still have a decent work area :D I did buy these really nice castors that are also leveling feet. They are rated for 4400lbs which should be plenty. The bench will have 6 legs with the fancy castors on the 4 corners and regular adjusting feet on the middle two legs. 
 



 

[DWyatt]

The base is made! This thing is way over built, but it is nice! I cannot say enough how impressed I am with these casters. The base weighs approximately 350 lbs and it rolls and turns so easy. Just have to finish drilling the holes to attach the top, then throw a coat of paint on everything.



 



 



 



 

[btulloh]

Where'd you get those castors?  

[DWyatt]

They are from CasterHQ and they are the TP-80F Leveling Caster. No affiliation from me, they cost $244 with shipping. I just happened on them by chance while I was trying to figure out what I was going to do to make this thing rolley. They have about a 1/2" of levelability beyond the wheel.

[DWyatt]

Holes are all drilled for attachment of the top and everything has been wiped down. My office hands didn't fare well with drilling 34 holes to 1/2" :D Time to start priming!



 

[DWyatt]

All primed and ready to paint tomorrow! The local hardware store anly had 3 cans of each color of primer so that's why the color looks goofy. 



 

[DWyatt]

All glued up. Time for some sanding at the joints then finish.



 

[DWyatt]

A couple more pictures with the clamps removed. I've got about an 1/8" of cup that should be easily pulled flat when I fasten it to the base. It is 35.5" tall and probably could have been an inch shorter, but it will work well.




 

 

[doc henderson]

fantastic.  came together well.

i see your glow in the dark Nalgene bottle (I think)  is it from Philmont by chance?  that is where we got ours.

[SwampDonkey]

Looks good, and rugged. Some fellas like big heavy furniture. ;D

You have a huge shop, so lots of real estate in there to move around in.

[DWyatt]

i see your glow in the dark Nalgene bottle (I think)  is it from Philmont by chance?  that is where we got ours.

Doc, my first glow in the dark Nalgene came from one of the SAE Mini Baja races when I was in college (collegiate competition series). It sustained a fatal fall about 2 months ago and I had to replace it with one I purchased online. I wouldn't go a day without it. 

[Andries]

Good looking table, very good.

[Ron Scott]

Very nice!

[DWyatt]

Let me tell you about how purdy this is with a coat of oil!



 



 

[Magicman]

A thing of beauty is a joy forever.

[SwampDonkey]

Great stuff. This for woodworking, or working on small engines? ;D

[DWyatt]

My wife asked me today when we were moving it into the kitchen  :D let's just say this is way nices than our garage sale table

[doc henderson]

you can tell her you are practicing to get it perfect first. ;D ;D ;D

[Mattjohndeere2]

Pretty awesome table! That'll be around for a long time!

What college were you for baja? I was on RIT's team, from 2010-12.

For years I've had a peice of bowling alley kicking around. Just got to making a base for it last week. I decided to go with cheap(er) casters and use some 3/4 threaded rod for leveling feet. I wanted those nice casters you used but I already have more $$ into it than I wanted to. It'll last forever though!



 

[DWyatt]

What college were you for baja? I was on RIT's team, from 2010-12.

I went to Ohio Northern from 2012-2016, but I wasn't real active on the team until my last two years. Those last two years, myself and my fiend who welded this table up almost single handedly build the entire car for ONU. RIT was a power house when I was in school, I assume that hasn't changed. 

[Brad_bb]

That top is probably too nice for an assembly table.  You can see the curl in the beech boards.  I'd use that top in the house, and buy 2x4's to glue up for the assembly table.  That way you won't care when it gets damaged or gets scratches or epoxy on it.

[DWyatt]

Brad, if you had seen these boards before they were glued up, you would've said they would work best as fire wood. I had a total of about 15 hours in just cutting the strips and running them through the jointer to get them even close to square/flat to be ready for glue up. Even after the glue up, before I ran things through the planer, I was completely convinced that the best place for this lumber was the burn pile. 

I've sawed & dried Beech twice now. I am not a Southerner, but I liken it to trying to make furniture grade lumber from Sweet Gum.

[SwampDonkey]

My winter project in the new shop is a nice wooden Veritas wood worker's table. I got the plans coming along with a couple bench vises, one is bigger than the other. Put the big one in line with the length and the smaller in line with the width. Been wanting one for 30 years. I also got the package deal HD had on a Dewalt thickness planer, comes with stand, extra blades and feed extension tables. I looked at spiral types, only ones I see are Chinese and I see that particular one has feed chain problems. It's a $2000 model, one could spend $15,000 on one to. They are 220V machines on cabinet pedestals. They are a nice to have item, but no way to justify those hard earned dollars. 

Built my 2x4" L shaped tool/machine bench with shelfing underneath yesterday. Melamine top. Went together quick, will last forever. I built one over 30 years ago at my old shop, has held up excellent. Easy to replace the top if ever a need arises, but can't see it.

A brandy spanking new Festool dust collector is on the way to.

[Magicman]

Your projects are always fun to watch, and I expect no less with this one. 

[SwampDonkey]

The thing about a work bench, you need to be able to stand close, that means you need room for your feet. Feet up against the wall means leaning over with more of an arch to your back. Leaning close is better than leaning farther away from the bench.  It will become obvious, right quick. A bench top with more overhang can be a solution.