Sounds like you have a well thought out plan,Tom. I presume that the weight of the table will be enough to hold it in place?
You might want to put the bench dog holes in it too,if you use pegs to stop your work. If you raise the edge banding 1/4" and lay the masonite flush,it works good too,keeps from fraying the edge of the masonite top. Might be hard to do on the vise end tho, might have to have a thin strip of hardwood across the end to protect the masonite where the vise is located, or build up the top of the vise with a piece of hardwood.
I would make the edge band flush with the bottom of the overhang too, facilitates clamping.
Sanding sealer and water based Poly works good for finish on the wood, no finish required on the masonite.
Thanks Herb. Good ideas, hadn't thought about the vise area of the masonite. Setting in a hardwood edge sounds like a good idea. I had planned to use a couple of wood screws to hold the top in place, which is why I figured on the vertical "trusses" fitted to the long edge of the present table.
I will likely drill up through the top from below the existing bench dog holes since they are already lined up with the vise. I don't use them much because they are hidden in a tool chest and hard to get to.
I was looking over the shop again this morning and realized that there is a high bench on one side of the table, and a set of shelves that hold plastic boxes with tools, accessories, etc. on the other side. I also think I'm going to remove a 20 x 36 steel shelving unit that is also on the bench side. Will move either my band saw or sander into that spot instead. That will open up the other end of the shop as well.
The shelving has a 2x4 piece of pegboard on it, but with the bench gone, I can tack that up to the studs, enclose the insulation there and gain a little wiggle room.
Think I will get rid of the bench and replace it with shelves to give myself a little elbow room. I have a drill press sitting on it now, but it can sit on a much smaller shelf instead. That will give me another 6 to 8 inches I can add to the table. The shelving will also let me put my planes, chisels and some other stuff up where they are quicker to get to.
I appreciate your input, would likely have missed those points. It really helps me plan to write this kind of stuff out, hope others get ideas and inspired by it.