Workbench Wednesday — Bench #2 (1990) Bench Auxiliaries

I was mighty pleased with myself when the bench was finished. It was easy to move, easy to set up and take down, good and sturdy with great clamping. Clearly, I had solved all the problems which led me down this path in the first place. However, a little use of the bench showed me that reality was slightly less idyllic.

Unfortunately, its lightness (55 pounds) which was such an asset in my master plan for the “perfect portable bench” was also a big liability once the bench ceased being mobile and was set up as a work station. The bench was so light I couldn’t really work it hard without moving it or even knocking it over. I had to figure out some way of weighting the bench while in use. My “no loose parts” vision was about to bite the dust.

Fortunately, the solution was as simple as building two thin (approx. 1 1/8″) torsion boxes to serve as shelves resting on the crossbar of the end/leg units on either side of the folding bracket, and which could be attached to the underside of the benchtop when not in use. By putting all my tools and supplies on the shelves, the bench now had enough mass for my use. It still wasn’t heavy enough for general cabinetmaking, but it was more than adequate for restoration.

Then a second problem cropped up. The working height for flat-ish or small objects was great, but setting chairs or case pieces on the bench raised them too high. For these taller pieces I needed a lower work surface which would still fit my ideal of lightness and strength. I could have built a lower version of the bench, but instead tried something different. This time I fabricated a torsion box about the same size as the bench top which would fit on a pair of small, low trestle horses. These trestle horses were made from lighter than normal elements, for example the main components were 1″x 1″ and the crosspieces 3/8″ thick.

Some minor modifications to generally employed designs yielded another light, strong and stable unit. By making the top bar of the horses removable, each post of the trestle could then become a tenon. Constructing the torsion box in such a manner that the bottom side had openings to function as extensions to the mortises already incorporated into the grid fitting the tenons of the sawhorse posts, the pieces fit together as a small worktable suited perfectly for holding taller pieces at a more comfortable height. While this new unit was not as “neat” as the workbench, it solved the problem. It also provided more flexibility than simply building another, lower table/bench.

This saga does not end here as I continued working on newer iterations of the concept, but those episodes will be recounted in future Workbench Wednesdays in a few months.

Next week – A derelict salvaged from the trash heap that was transformed into a little jewel.