Building the Paulk Workbench, Part 2 (Torsion Box Body)
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- Опубліковано 3 тра 2019
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This is Part 2 of my multi-video series showing you how I made my Paulk Workbench! This workbench was designed by Rob Paulk who has a ton of experience with contracting and woodworking, and his design represents his knowledge of both great utility and mobility. The two-part top allows it to fit in a van or a truck, and makes it easy to move around the shop or take on site. It’s also incredibly sturdy! I documented my entire build and I’m excited to bring you this comprehensive, instructional, multi-part video series on how to make it! I hope it helps you as you make your Paulk Workbench or a variation that fits your needs.
Part 2 of this multi-video series focuses on the main torsion box body, top and bottom of the workbench/assembly table. (You can learn more and download the plans on the Ron Paulk Website here: www.paulkhomes.com)
//Part 1 of this multi-video series focuses on the main cuts for the workbench/assembly table and how to make the saw horses. View it here: • Building the Paulk Wor...
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Details on this project below.👇🏼 For more projects, check out fieldtreasuredesigns.com/blog/
Check out my podcast, The Field Treasure Show! spoti.fi/2CSJgFF
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////// MATERIALS USED
(1) 4’ x 8’ 1/2” Foam Insulation Panel
(5) 4’ × 8’, 1/2” Plywood
(1) 1 1/2” Polypro Webbing: amzn.to/2EfPNL9
#8 1/2” Panhead Screws
////// TOOLS USED
Bosch Circular Saw: amzn.to/2GJnPt3
Kreg Rup Cut Guide: amzn.to/2EgrhtC
4’ Level: amzn.to/2X78RCG
Stanley Powerlock Tape Measure: amzn.to/2IlJhGM
Milwaukee 4 1/2” Hole Saw: amzn.to/2Eh4RIx
Bosch 12v Jigsaw: amzn.to/2DThxUq
Random Orbital Sander: amzn.to/2SBg5My
Sanding Discs: amzn.to/2M98HWy
Bosch Router: amzn.to/2Efi84h
Bosch Colt Router: amzn.to/2GwachE
1/4” Roundover Router Bit: amzn.to/2EgQRyC
3/4" x 1-1/4" x 1/2"HSS Onsrud Spiral Bit: bit.ly/2GtXlfH
3/8" x 1-1/4" x 3/8" Carbide Onsrud Spiral Bit: bit.ly/2GtXlfH
1/2” to 3/8" Bushing Adapter: bit.ly/2EfB2bn
18v Bosch Drill/Driver: amzn.to/2SB1kth
12v Bosch Drill/Driver: amzn.to/2BWJHNl
Sliding Square: amzn.to/2Ef0mhv
///// PHOTO, VIDEO & EDITING I USED
Canon 80D: amzn.to/2VHhzab
Canon 10-18mm Wide Lens: amzn.to/2CNa2zh
Canon 50mm Lens: amzn.to/2COnzq8
Canon 18-55mm Lens: amzn.to/2Mepfwo
Rode Video Mic: amzn.to/2VIBR2V
iPhone X: amzn.to/2VrCf64
Tripod: amzn.to/2R9Qq12
iPhone Tripod Mount: amzn.to/2SzTd09
iMac: amzn.to/2VrstAJ
Recording to iPhone: amzn.to/2C0UshJ
Recording to computer: amzn.to/2BWNH0j - Навчання та стиль
Great job, Andrew! You made it look easy. Your enthusiasm adds to stimulating us to get it done.
Thanks Johnny. Really appreciate that.
Not only is this a really well made "easy listening" kind of video, it was super enjoyable! Narration was pleasant and very well paced. Shots progressed very sensibly. Music was very well selected and appropriate (not overly noisy or overpowering). I followed the whole build and it was only half-way into the second video that I realized how long I've been watching! Great job and a lovely workbench! .
Wow Daniel! Thank you so much for the kind and detailed words of encouragement. I really appreciate you taking the time. Cheers!
Great Job, looks amazing! Can't wait to get my own Paulk workbench built.
Thanks Michael! Please send me a picture of your finished project as I'd love to see it.
Very well made video, AND bench mate. I hope to build myself one soon and I’ll be using your vids on my iPad as I go for step by step instruction.
Subscribed !
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Thank you, Andy! And cheers for the positive comment from over in the UK. Make sure you send me your finished build. I will love to see it.
Great job kid! I've been thinking about this very work bench. You got me sold!
Thanks, Daniel! Good luck on your project.
I'm so glad I came across your video as I'm very very limited on storage. Modifications will be made to this as my tablesaw(inverted skill saw) and router, because I build cigarbox guitars be no bigger than 4x6' +/-. Thank you for sharing this, it's just what I've been looking for!
Sweet! I'm so stoked Will.
New to woodworking; have watched dozens of workbench videos; they are way over my head/experience level. Although the Ron Paulk workbench is also way above my experience level, it was a pleasure watching the video. With total respect for all, I could relate to your video better than the professional (with decades of experience) woodworker videos. Quite frankly, I'm not smart enough as a DIY hobbyist nor do I have the time and resources to invest in the outstanding tools I see on most workbench building videos. Still, I'll continue researching video's and the internet for affordable, simple workbench plans I can handle as a novice! Appreciate your enthusiasm and simple, straightforward approach to woodworking. Jim in Georgia
Wow! Thanks for the kind words, Jim. They sure go a long way here on youtube. Good luck to you!
Great job! Congratulations!
Thank you!!
Great job and GO BIG RED!!!
Thank you!
You could use double sided tape instead of clamps when routing the spacers. Great video.
Great tip! Thank you!
Nice job. If I had the room I would build one myself. Enjoy
Thank you! Maybe one day.
I went with sand a/b ply but I love the look of yours….it looks like tiger tripes 🐅. Your videos have helped a ton in getting this thing started 👍
Heck yea thank you! So glad it helped.
Great Job!
Thank you!
You do such a great job of explaining everything so well. I wish I had your videos several years ago, when I made this bench. I used 3.4 baltic birch ply on the top and bottom, and didn’t have my spiral up/down bits the. So, I burnt through a straight bit instead.
Thanks Andrew! I really appreciate that.
Great video, Great commentary. Wish I saw this before I built my work bench a few months back....grrrrrr
Thank you Vimaan!
Thank you for this video. I plan to do just what you did. Seems the hardest thing in making the Paulk work bench is not having one to make it LOL.
i
You bet! Haha. I felt the SAME way during my build. But now I have it thankfully. Good luck to you!!
Nicely Done 🔨📐
Thank you!
Hey Andrew, nice video, I just caught it.
I built my Paulk bench about four years ago. Also bought the plans and built the total station.
The last several videos Ron has made featured some designs I gave him.
Check them out if you get a chance.
I built my first bench totally my hand, as you have here.
One thing I did differently; for the template to rout all the large holes, I simply extended the “ears” on each end which left plenty of room for the clamps. I then nailed blocks in the bottom side so that it placed the object peace center line.
Hi Kevin. Thanks for the information! I will definitely check it out. I love new ideas.
Thank you!
You're welcome!
Great video Andrew! Thanks for the posting. I'm about to assemble mine. I've seen several comments and suggestions about the template routing and I think I have the perfect solution. What I did was set the template (or the blank to be routed) on a larger piece of scrap plywood, then screw strips of 3"4 scrap wood next to the template (or blank) so it can't move. Then put the blank on bottom and the template on top inside the screwed down strips. That will hold them in place while you route, and won't be in the way of the router base because the two pieces of 1/2" ply stacked are taller than the holder strips. Boom! Easy and FAST. And most importantly accurate.
Thanks! Also thank you for taking time to share the knowledge you have and what your plan is. That is a great idea. Please send me your finished project via email or social media as I'd love to see it!
thanks! good job
You bet! Thank you!
Just a quick one Andrew, you should run the rounded edge of your router base against your guide, if you rotate it at all it won't matter, the plane is identical. If you hiccup slightly on the straight edge you'll screw your line up immediately. That's what the large round edge is for.
Thanks for the tip!
Great vid! suggestion: maybe screwing the template to the workpiece like you did with sawhorse template would've been quicker and involve less movement, seeing as though the router work could be down in just one pass.
Thank you!! And great advice. Thanks!
Or possibly using painters tape and CA glue. That way no screw holes to fill.
When routing spacers maybe you could screw template and stock through foam into plywood under foam slo no clamp would be needed?
Definitely a possibility!
I got same thought's ))
I built a 1" form around mine so they were locked in and I didn't have to fuss with clamps and I didn't want to screw through them. Probably being a little OCD but been treating everything like I'm building some high end furniture rather then a workbench lol I know it will get worked to death and start getting beat up but right now I'm trying to make it as perfect as possible lol
Very good video. Nice work. Gonna do a version of this but a rolling workbench style. 2 tables each 3x5 that I can put together to make 3x10 or 6x5 with pipes running through to connect
Thank you! That sounds like an awesome idea.
Hi Andrew, quick question... Where did you get the 3/4 upcut router bit... I am having a tough time finding one... Can find 1/2 all day long! Thanks!
Hey man! Great question. I bought it from Lee Valley online. I have the link below in the notes on the Part 1 Video in the series.
Awesome video with super clear instruction and totally helped clarify a lot for me.I bought Ron Paulks plans but really appreciate the video.
Im building my self a Paulk workbench but my local home center didn't have the size right pipe .
Just wondering if 4 foot, 3/4 inch pipe would suffice vs the 6 foot 1 inch. I have the same dewalt jobsite saw you have and was curious if the weight of the saw/ ever tipped the bench?
Thanks Denis! That is EXACTLY why I made this video. Great question. I have not had any bend with my table saw and stand and definitely not even close to tipping the workbench. Although i would hesitate on using 4' simply because it won't reach in as far into the torsion box allowing it to go through the 3rd support which will reduce the integrity of being able to hold the pipe in place. However I can't be sure until it's tried!
@@diywithandrew Thanks for you input. I'll definitely be using a longer pipe. I cant wait to have my bench finished to work on it and get my saw off the garage floor- it's back-breaking lol
Awesome! Yea I hear you on that. Send me a pic when your finished!
Great video brother..came out great. I have my tops,bottoms, spreaders and horses cut,routed and sanded. I still have to drill my dog holes but probably jumping back on it tomorrow. I wasn't gonna do the table saw thing bc I have the Bosch on gravity stand but after watching what you did I'm gonna build the box anyway just incase I decide to drop it on. Your box was a awesome addition..thanks for sharing! Quick question..with the pocket holes for bench assembly..which screws did you use? I was planning on the 1" bc it's 1/2" to 1/2" but just wanted to make sure that's what others are doing? Am I correct with the use of 1" kreg screws or did you happen to use 1.25" screws? Thanks again for the videos..very well made. Have a goodnight and stay safe.
Thanks, Bill! Good to hear you are coming along. I love the Bosch gravity! But yea, I think that is a good call just in case to build the box. I've got a simple plan on my website here that might help, gumroad.com/l/tablesawmount .. I ended up using 1.5" screws and wood glue. The screws are essentially there to hold it until that glue dries. Hope that helps! Thanks again and stay safe as well.
Awesome job Andrew! Your videos are well made. Hopefully you will find the time to make more as your channel grows.....AND IT WILL!!! SUB"D ;)
btw, cover the car before you make saw dust! Lol
Thank you Joe! And yea that is a good idea.
I like the dewalt chop saw you are using with the light on the guard. Is that stock or a modification?
Great eye for detail! It is a stock part of the DeWalt Compound Miter DWS780 and honestly the very best feature.
@@diywithandrew Thank you for answering. DW and other brands need to add a mod or some add on for their saws. Good lighting and visibility are key to accurate and safe cuts.
Great video!! I'm in the process right now of building mine. Have it all cut out and at the assembly step. One thing I did NOT seem to find on the plans was the length of the pocket hole screws. Can you tell me what you used? Thanks!!
Thank you Don! Glad to hear you are making yours happen. Since you are attaching 1/2" plywood to 1/2" plywood, the jig setting is 1/2" and the screw length is 1". Just use a low setting in the drill so that you don't go through the top. Just enough to hold the boards together while the glue sets. Hope that helps!
@@diywithandrew Great! Thanks. Did you have another video you haven't uploaded yet? I was hoping for some specs on your table saw mount. As you know, the mounts in his plans were for a different saw that mounted higher up on the saw. I have the DWE7480 (same size as your DW745). So, I knew I had to modify the mounts. Just couldn't decide on the best way. Now that I saw your mount, I may have to go with a drop mount box as well. Either that, or I was thinking of just making a simple rolling cart and butting it up to the bench. That would probably save some work, IMO compared to the pipe mounts, as well as leave more room inside the bench frame. Anyhow....wondering if you had a video on the mount somewhere?
@@donmeyers3090 You bet! I have Part 3 in the works where I am explaining exactly how I built my table saw platform/mount. I will be posting that one soon so stay tuned!
@@donmeyers3090 Hey Don just wanted to let you know that Part 3 is finally finished and now available!
Don Meyers j
Is the template a bit bigger for the side pieces to allow for the coller etc, I thought a flush bit might have been used
Yes, it was just a bit bigger and I ended up not using it in the build.
Just fasten the template with two small brads/finish nails. Then use a stiff putty knife to pull up the template. Easy!
That's a great idea. Thanks for watching and sharing!
How to make life difficult. You made that hard work I tapped out after a short time I'm afraid.
Sorry to hear that. It was hard but I’m thankful I got it done. I still use this workbench almost every day.
Very nicely done, Andrew. May I add a production suggestion? I spent 47 years in radio and TV, so I know a thing or two about audio levels, so please believe me when I tell you that you do not have to crank your music up so much when you're not talking. (I get the distinct impression that you were advised to make all of your levels 100% on your VU meter all the time.) Your music levels are perfect when you're talking, but I suggest you pot them up by only 10 or 20% when you're not talking.
Thanks, Scotty! Really appreciate you taking time to offer some great suggestions too. Thank you.
Use double stick tape to hold template!
I had considered that but wanted to make sure it didn't move since template routing can be strong, moving the piece off target. I also preferred to small holes that could be filled rather than dealing with sticky tape residue.
Great video! How much do you estimate for the weight of each half of the work bench?
Also, how often do you assemble/disassemble the bench and how is it holding up?
Thanks man! Great question. I want to say 75lbs but I should weigh them and make sure. The pipes within make it easy to grab and move. I've got a breakdown/setup video if you need to have a reference. I have broken it down and moved it about 5 times. It has been just about a year and it performs wonderfully! I need to do a video reviewing it after a year actually. Thanks again for commenting!
Field Treasure Designs m
Hey, great video, as always. Since these pocket holes are facing the edge, rather than the inside like most pocket holes scenarios, I'm curious if you had any issues the screw coming out of the side of the workbench top?
Thanks man! Great question. I made sure and got the glue in there and then screwed each screw in gently enough to secure the wood until the glue dries. But yes, there were a few times I needed to back out the screw a tad and I remember one that I had to grind/sand down.
@@diywithandrew Thanks for the quick, reply. Gotcha, so basically just pay special attention and lower the drill clutch ahead of time!!!
I
Do you by any chance still have the plans for the saw horses that you built? I have tried to find them on the Ron Paulk website but he has updated to a new style that I am not thrilled with. Please let me know. Thank you for your time
Shoot me an email and I’ll see if I still have it. My email is located in my about page on my channel.
Watched video, I have made a table 1/4 the size of yours, works well. I live only 4 miles from Newcastle, I was brought up in Newcastle so wonder why you have our "Necter of the Gods" sign on your wall?
Thanks for watching! Haha! Glad you noticed the Newcastle sign! So that was a gift from a friend who said he found it hanging out of a dumpster?? Since I love Newcastle beer he knew I’d like it. So that’s the story!
Maybe some drywall screws would help keep alignment. less clamp setting
Great idea!
Looks great whats the width of the side pieces?
Thanks! .. 7 inches
Field Treasure Designs total height would be 8 inches? I am out measuring in the garage a looking to see where it would fit standing up.
I can't help but wonder if it would work to cut full strips in both direction but cut 3/4 wide 1.5in high slots on all the strips and then fitting them together. That sounds a LOT easier than cutting little pieces and then attaching each one.
That’s a cool idea! Thanks for sharing.
personally i'd set the new clamps before removing the original ones so the template didnt move and I'd use double side tape.. overall love the project and the commentary
Great ideas! And thank you for the comment.
Great video. I'm getting ready to build mine. I'm getting a hole cutter 4.5" today. I like your router trick to make duplicates. I think I may use a couple of long screws and screw down the spacers to the table (with insulation underneath) and then route the interior like you did. I think that way I can make a complete pass without rearranging clamps. Think that works?
Hi Craig. Thanks! I think that is a clever idea. I hope it worked out!
You have 2 spiral bits listed. 3/4" and 3/8". The 3/4" is for drilling the holes in the tops. Did you use the 3/8" for cutting your sawhorse and side templates? I think the video mentions 1/4" so I'm just trying to clarify. Thanks.
Great questions! You are exactly right! I might have misspoke on the video commentary. Thanks for clarifying and best of luck to you on your project!
good design .... then by using one type of material for all parts, i think it is better trying this design by using cnc machine to producing parts required for the table.
Thank you! Yea I think I agree
What is the purple top made of on the workbench?
It’s 3/4 inch panel insulation that I used for sacrificial cutting.
I didn’t catch you, is that 1/2 inch plywood?
yep! Incredible strength while being fairly light.
I 'm planning to use osb am i making a mistake?
Great question. I wouldn't do it since it is such a rough material and not as dense as ply but hey I'm always up for trying something new. Good luck!
Osb Will work great, and much more lighter. .
16:35 get a crosscut sled. you don't want one of those boards to accidently kick back on you.
Solid advice. Got one in the works!
When you move the clamp - add additional first then remove the one in the way. Replace asap
Great tip! Thanks for the comment.
When cutting the spacers, you could have just screwed them down like you did for the saw horse.
I had thought about that, but I didn't want the holes in them. In hindsight I was probably being too particular. :)
I'd be interested to know how happy you are with the strength of the benchtop, as you sawed and drilled away quite a bit of the webs. To my way of thinking, you should have either made them higher or not removed as much material.
Thoughts?
Hi Marty. Yes. It is very strong due to the torsion box design and glue up. If I remember right, I jump on it at the end of this video and it doesn't even move. What I love about the design is that the boxes are light for when they need to be transported but also super strong and stable.
Yanno, if you'd just cut one the two center holes from the LONG side first, then stuck a couple of the offcuts under each side and in the middle to both keep it level and give the clamps something to bite on without inducing flexion, you could have just clamped TWO of the short ones side by side beneath said long one and routed them without obstruction...
Well where were YOU when I made this?! LOL. Great tip.
Is it made of 1/2inch plywood or 3/4 inch plywood?
Great question! I made it all our of 1/2 inch. It would have been way too heavy and not needed in my opinion after using it for almost 2 years now.
Field Treasure Designs thank you 🙏
Many woodworkers seem to have found that joining 1/2 inch ply is pretty problematic. Can you comment on that and tell us what screws you used.
Hi David. I certainly understand that. I used 1 inch course pocket hole screws and 1 inch deck screws (for the bottom). I had to be very careful but with the glue and going slow and steady not overdriving the screws. It worked great!
Field Treasure Designs panhead or flathead? Per what I see on Kreg site should be panhead?
Double-sided tape or four brad nails would work well to hold spacer template to blank for routing.
Great ideas! Just not the easiest to get off.
Double headed nails pinned at the extreme corner edges . . . easy to get off later and might still give your router enough room to turn the corner?
How many hours did it take?
Man I cannot remember.
temporarily screw the template to the spacers with dry wall screws.
If it hasn't been said already :-)
It's already going to be so weak. I think screws through would be the final screws in the coffin...
Definitely not weak at all. That's why I love the Paulk design.
Great thought!
There is no way this will last!
Been almost a year and it's still just as solid. Feel free to check in in another year.
where do I download the plans from
thesmartwoodshop.com
How much are the plans ??
I want to say I paid $20 but can't remember.
Interesting that the holes where cut away, then the pole supports where added back. Shows bad design, lack of for thought, changes integrity of each panel too.
Glad the Vid described the torsion box though.
I don’t agree. Ron Paulk designed this very well and did not lack for thought. Certainly there are many different ways to design this for use and you are entitled to your opinion. I have used this for over 3 years and there has been no integrity failure as the pole supports spread out the weight along the inside. Thank you for at least showing appreciation for the torsion box video.
That's 12mm ply isn't it?
It’s 1/2 inch which I think is a little over 12mm.
@@diywithandrew Great work by the way!
It's RON Paulk...
It certainly is.
_THICKNESS_ is a little more than 1/2". Width appears more like 7-8".
It's 1/2 inch plywood.
Dane cook?
Haha. I have heard this before. I don’t see it but i guess others do!
@@diywithandrew great video man... you're very skilled... and you made an awesome workbench
Using a Dewalt Job Site to get "accuracy" is sort of cringe, but I love it for work-site benches.
I think DeWalt allows for as much accuracy as possible with a job site saw. I’m happy with it
its plywood, very hard to split.
:)
I don't get it. That looks like a good design for scraping your knuckles when reaching for tools under the work surface. It also looks like a good place to accumulate loose screws, and nails, and sanding dust, and pencils, and...
Different strokes for different folks! Probably 10,000 workbenches to choose from on this great earth.
I built one of these years back when they were popular. Waste of plywood and money. I built a conventional table with 5 inch casters and never looked back.
Nice. That's the thing about this great planet. Different opinions, needs and options.
It should be called building a welding table out of wood, that's all it is.
Or a "workbench". Lol
You should've just used screws with the template.
Yep. Just didn't want the holes but in hindsight it would not have been a big deal.
Good job man, nice work ! But the music ... ouch
Thanks! Haha, yea my latest videos don't have the tunes.
Fourzner
err. thanks?
Great videos but I can do without the annoying music. At least lower the music volume.
Totally agree in hindsight. I’ve removed it from my other latest videos.
No music would help, it's just NOT useful for people trying to hear you
Thanks for the feedback! I am about to release non music versions.
don t like the bench
That's the good thing about the earth. There are a LOT of other great options on it.
Haha it never ceases to amaze me that humans can be so terrible
You’re just copycating!
Are you serious? I’m abundantly clear where I found this design and proud to build and share Ron’s design with others.
And now it's just a matter of ignoring the number of times this guy says 'now it's just a matter'.
An over produced video with a hyperactive voice-over. Quite wearing to watch. Not recommended.
It was "just a matter" of time before I saw your hyperactive comment. This comment was quite wearing to read. Not recommended.