I need to make a flat tabletop worksurface 40" x 96". It will only be
supported 3 spots over the 96" length at 6", 48" and 90" from either
end. I want to come back and measure it years from now and its still
flat. The other criteria is I only have 4" of clearance below the top.
Flatness should be what is praticle with an 8' straight edge and feeler
gauges. Ideally a maple top that I could put an mdf wear surface on
would be great except, I haven't had any luck finding one that size, and
the cost of one smaller plus shipping is pretty hefty, $400+. It won't
be supporting lots of weight, just the usual woodworking worktop.
I am using my Dad's workbench. It is a 36" x 72" solid wood door, 1 1/2"
thick from Weyerhauser. This door is 60 years old and still dead flat
across the entire surface. It is supported by a 3x3 post on each corner -
no support in the middle. This thing is so heavy my brother and I can
barely carry it.
(2) sheets of 1/4" plywood
(1) sheets of 3/4" birch plywood
(2) sheets of 1/2" mdf
Staples and gun.
Make the frame out of strips of 3/4" birch ripped to 3",
with interior seperator strips "about" 6"-8" apart.
Skin it over on both sides with 1/4" ply using glue and
Top it off with 1/2" mdf.
Very flat and very strong.
How flat depends on you.
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