What to use as a bench top

[biscuit141]

I am building another bench. On my first bench i used 3/4" plywood as the top. For this bench I was thinking of doubling up the top but I didnt know if instead of using 2 pieces of plywood if I could used once piece for the top layer and something cheaper like MDF, particle board or similar as the bottom layer. Those bards are usually around half the cost of the plywood. Any suggestions?

 

[onelochevy]

Lots of folks on here suggest using a solid core wood door. Try to find one that someone is getting rid of. Should make for a very durable / cheap top.

 

[Jack Olsen]

Yes, it will work fine to put a cheaper type of lumber under the top plywood layer.

If you want two layers of plywood, one way to save a little money is to cut a 4x8 sheet in two -- but not in half. Most people will find 24" to shallow for a work bench. So cut it at 26/22 or 28/20 and then position it so the double thickness is where you do most of your work, with a single thickness in the very front and/or in the very back. You'll get most of the sturdiness of a 1-1/2" thick top without having to spring for two sheets of stock.

I don't have a great picture of it, but if you look at the bench folded up against the wall, you can see that I have 2x 3/4" sheet for the rear 20" and then a 2x4 crossmember capping where the 20" deep support sheet stops. It might not look like it, but this is a very sturdy work surface.

But if it's a fixed bench, you can also put a few inches of space in the back, too. Again, the point is that you need the reinforcement (usually) right in the middle of the work surface.

 

[biscuit141]

Thanks Jack. I never thought of that idea. However, I already made my bench supports at 29" for the top with a 19" shelf underneath, so this will use a full sheet of plywood right there. I was thinking of doing another 29" piece under the top plywood and then cutting the remaining 19" piece in half and putting two shelves on the wall above the bench to help keep parts, supplies and tools off the bench while I am working on a project.

I am mainly looking for ideas on alternative wood to put under the main plywood.

 

[evintho]

I built mine using two pieces of 3/4" plywood and topped it with a piece of 1/8" hardboard framed with 1-1/2" strapping. The hardboard is screwed to the plywood with countersunk woodscrews so when the hardboard gets too torn up, I can easily replace the bench surface. I just recently replaced the hardboard. The first piece lasted me 10 years!

 

[bigjmcconnell]

Lots of folks on here suggest using a solid core wood door. Try to find one that someone is getting rid of. Should make for a very durable / cheap top.

This is what I plan on doing on my next project. I'm actually planning on using it on top of my roller toolbox.

 

[metal1313]

i did 2 layers of 3/4 osb covered with 1/8'' plate, that is ususally covered with some ply pieces that i clamp down for general work, or to screw stuff to

 

[NUTTSGT]

I used 2 layers of 3/4 PT plywood, glued and screwed together.

 

[digdug18]

I used one layer of 1" plywood, plenty strong enough for an engine block, I know that because their is one on there right now.

Andrew

 

[Kevin54]

The thickness all depends on what your intentions are as far as using it. One sheet of 3/4" will work just fine, but add additional braces underneath. When I built my bench, I braced it with 2x4's every 12" underneath. My top is your standard counter-top w/Formica from Lowes. If you are going to be slamming differentials and transmissions and engine blocks on to the bench, then I would say go with doubled up 3/4" plywood. If you want a smooth top to put Formica or something similar on, then go with a piece of 1" MDF. For general wrenching, leaning or sitting on the bench-top when you are having a beer, or just using the top for your toolboxes....two pieces of 3/4" is overkill. The floors in your house aren't that thick.

 

[ibedayank]

i used some 2x6 tounge and grove stuff i had..old flooring i think

 

[petee_c]

My workbench is a design from a black and decker book that I borrowed from the library. It is 2 layers of 3/4" plywood for the top. Works well. I think the design called for a hardboard top, but I skipped that. I suppose if the top gets too beat up, I could unscrew it and flip it over to expose a new side.

Unpainted, stained with oil, misc grease etc.

P

 

[Rickstir]

My brother gave me a piece of butcher blockk, 2 X 8 Ft x 2 inches thick. Love that boy.

 

[Mikea57]

I've got just plain old counter top right now but the tool benches I grew up with were all 2x10 or 2X12 lumber lag bolted to 4X4 legs. My Dad, Grandfather, everybody I knew that had some sort of workshop had that setup. Of course if you HAVE to have a smooth surface you'd need to go another route.

It's old skool but it works...

 

[mmhouse]

1-1/8" 2-4-1 Sturdi-floor plywood.

This stuff provides great strength in a single layer and because it's made for subfloor there are no voids under the face. The face is also typically touch sanded so it's reasonably smooth.

Most true lumberyards should have it. I'm not sure about the big boxes.

 

[talonman69]

I used a section of a bowling alley (ie thick, maybe 3-4"). Got more left if anyone is interested in Maryland.

Rob

 

[Falcon67]

I've got just plain old counter top right now but the tool benches I grew up with were all 2x10 or 2X12 lumber lag bolted to 4X4 legs. My Dad, Grandfather, everybody I knew that had some sort of workshop had that setup. Of course if you HAVE to have a smooth surface you'd need to go another route.

It's old skool but it works...

Note - that was back when you could buy old growth lumber that was less likely to split, cup, twist, etc as it aged. I'm thinking about that option with a 3/4 ply top over the boards, but I'd build a 1" steel tube frame with at least 4 cross pieces inside 8' to bolt the 2 x ? s down and try to keep them flat. 2 each 2x12 with a 2x4 backer is exactly 24", so there is some handy math in it. Lumber is cheaper - a 2x12x16 is $14, a 4x8 sheet of 1 1/8" Sturd-i is $39.

 

[Scoutman]

I'm using laminated 2x4's (on edge) to make up my latest workbench top. I'll shave a 1/4" off each one to get a flat top edge and then glue and screw each new layer on till I get the width top I want ~24". Should be uber heavy and very solid. I'll finish up with a belt or disc sander to even out the surface and make smooth.

 

[Steevo]

I am building a bench for my lathe right now, and I am using a top made from a re-cycled office counter top (1-1/4" thick osb-like material with heavy gray laminate) and am putting a 12ga steel cap over that. I had the cap folded by a local steel place for $107 out the door.
I am using a frame that has 2x6 stringers, six 4x4 legs and 2x6 braces running front to back every 12" for top support.

 

[Chloe Taylor]

Lots of folks on here suggest using a solid core wood door. Try to find one that someone is getting rid of. Should make for a very durable / cheap top.

Can i ask the question as to why wood gets preferred over steel while going for and making a bench top....

 

[csp]

The post you quoted has the answer. Durable and inexpensive for what 90% of the people use their bench top for.

It's also easier for most people to modify to their own specifications.

 

[Farmallgray]

I built two benches for my shop using Kubota compact tractor crates for the frames. They are made from rectangular steel tubing and were free. I had a bunch of rough cut 2x6s leftover from my building and used them for the top. I then covered that with 16ga sheetmetal. I used plain steel on the first one and I have to wipe it down with oil to keep it from rusting. The second one I used galvanized steel and it is much nicer and also brighter.

 

[Falcon67]

Can i ask the question as to why wood gets preferred over steel while going for and making a bench top....

Price. I have had a bench top cover made from galvanized, which is nice. Most custom duct work companies can bend up a galvanized top fairly cheap. Lots of people don't have a way to easily handle a 4x8 sheet of steel or cut it, especially in thicker dimensions. FWIW, I've built and serviced many engines and transmissions on a 2x8 bench I made with a single layer 3/4 ply top painted with gray porch/floor paint. 12 years and its good to go still.