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post #1 of 27 (permalink) Old 03-31-2018, 09:40 PM Thread Starter
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Default Mobile Work Bench

I’ll post this here because it actually is going to be a table mounted router as well as a work bench when I’m finished. This is the progress I made today. Top is not mounted yet. The router will go in the square that is cut out in one half of the bench. That portion of the top will be double thick. Probably overkill for a DeWalt DW611 router, but I like things heavy duty.

There will be a receptacle in three corners and a switch in the fourth. The switch controls one receptacle while the other two are hot when plugged in. I left only a short cord hanging out to be intended for use with a longer extension cord. Thought about hooking a 100’ cord up permanent but this thing is already heavy so I nixed that idea. It will also have a place to use my swing arm work light as well, and possibly a side pocket for stowing a tape and pencil. I can use clamps along all four sides, and have plans to make a jig for clamping door slaps on their edge on the ground along one side of the bench for routing hinge mortises. This is primarily for work, as I am a maintenance man for an apartment complex.
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post #2 of 27 (permalink) Old 03-31-2018, 10:09 PM
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Nice job Duane. It looks like it should be pretty handy. It doesn't need to be double thickness for the router but it might be handy when used as a workbench. One suggestion though is to duct tape or caulk the holes in those electrical boxes to keep dust out of them.
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post #3 of 27 (permalink) Old 04-01-2018, 06:54 AM
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Nice job Duane. I'm sure you will get many years of good use out of it.
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post #4 of 27 (permalink) Old 04-01-2018, 06:58 AM Thread Starter
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Thank you. I’m trying to build in as many functions as I can with this. I made it right at 34” tall so it can serve as an infeed or outfeed table for my table saw. The extensions are higher than the surface. I was going to built the top flush with them instead but that meant sacrificing the outfeed function, as well as needing more wood. The extensions are easily removable for table saw use and I can simply slide them out if I just need them to be out of my way for other work.

Also wanted storage in it but that’s probably unnecessary since it is meant to be mobile. I have the space for some storage such as a couple of Plano Stowaway boxes for parts but that would add weight and require that the top have a lid in it which would complicate things to make sure it all stayed together when moved. I don’t want to make it to “gimmicky”. However I do want to think about making the router fence double as an upright clamp jig, and for that matter I may make it more like a box so when I’m using the bench for other work I can toss parts into it that I don’t want rolling off the top. The router isn’t meant for precision work, just utility stuff so it won’t matter if the fence gets dinged up some by being multi-functional.

Since I need to be able to mortise door hinge attachments on doors from 24” to 36” then I’m planning to make an H shaped jig to clamp along one edge. The horizontal bar will extend past the uprights and let me use that to clamp it to the bench. The vertical bars will hang down and allow me to clamp a door slab on edge to them to stabilize it for work. This happens often where I work. These cheap hollow doors get busted up and replaced a lot. I get a door slab and cut to fit it’s been hard up to now but I’ve managed to use a park bench as a workable surface a few times. No more!
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post #5 of 27 (permalink) Old 04-01-2018, 07:24 AM
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Nice job Duane....
I like it...

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

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post #6 of 27 (permalink) Old 04-01-2018, 07:46 AM
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Nothing nicer to have than a portable work surface!!! This should serve you well Duane.
Couple of thoughts if you don't mind....

Go with ground fault outlets.
mount a magnetic tool holder to the side
install a 3/4" x 2" x 6" piece of angle iron for use as an anvil. 1/8th thick
Configure the opening for the router so that it could also double as a opening to install an inverted circular saw (think jobsite table saw)
a couple of t-tracks for use with hold downs
Pneumatic tires

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post #7 of 27 (permalink) Old 04-01-2018, 09:03 AM
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Great ideas Bill. I like the skill saw mount the best! If I remember right, you only need the first outlet to be a ground fault outlet (I think that is code here). It will break the circuit for anything after it (I think?). Does anybody know for sure?
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post #8 of 27 (permalink) Old 04-01-2018, 10:29 AM
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Wow, for a purpose built portable workbench, this one gets an A+. My did a lot of apartment maintainence for the 6 units they had. He would have really loved something like this. Plumbing was his nemisis. He would have needed a thread cutter installed since everything back then was galvanized iron pipe. Personal question Duane, is this a job you took for retirement or do you own the apartments? Just curious.

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post #9 of 27 (permalink) Old 04-01-2018, 10:38 AM
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Quote:
Originally Posted by Tonto1 View Post
Great ideas Bill. I like the skill saw mount the best! If I remember right, you only need the first outlet to be a ground fault outlet (I think that is code here). It will break the circuit for anything after it (I think?). Does anybody know for sure?
It depends on how you connect the GFCI into the circuit Quenten. The instructions come with the outlet for wiring to single or multiple.

The outfeed table rollers may get in your way at times Duane. For example if you wanted to lay a sheet of something on the platform to mark it out. Could you attach the rollers to wooden blacks and then hinge the blocks with butt hinges and pin them in position when needed?

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #10 of 27 (permalink) Old 04-01-2018, 11:25 AM
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Good to see a job like this!! Congrats
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