Author Topic: New (CNCd) box beam workbench, with Festool holy system!  (Read 2855 times)

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Offline fritter63

  • Posts: 1341
New (CNCd) box beam workbench, with Festool holy system!
« on: January 16, 2017, 03:09 PM »
I've been planning to build the "3rd generation" of my workbench box beams for quite some time and finally got the time in between guitar builds. This time I decided to use the CNC machine for all the holes.

These started based on a radical design from FWW (http://www.finewoodworking.com/2008/12/01/forget-what-you-know-about-workbenches), but I've been modifying it every time to suit my needs and improve it as I see fit.

Here is the 2nd gen (which as you can see has not been demoted to an outfeed table for the TS):

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Two rows of holes on the top, one on the side, and I left the bottom off thinking I didn't really need it. But as my mechanical engineer nephew pointed out, they weren't as strong without the bottom part, and indeed they have sagged between 1/32" and 1/16" over the years. Also, those interior partitions were ALWAYS in the way. Everytime I went to clamp something, there was a partition in the way of the festool clamps.

So I decided to do them up as proper box beams, with a bottom, and create cutouts so I could still use the Festool clamping elements knobs to secure them. I also made them based on a multiple of 32 mm dimensions, 3 rows of holes in the top and 2 on the sides. I used dominos for alignment during the glue up, and then just glued everything without any other fasteners.

Note that decided to use 1/2" ply for the top this time just to save weight. I'm surprised at how much lighter they are actually. One last thing, I chose to laminate the tops in formica (bright green of course!) to make them resistant to glue and chemicals.

Here are some pictures, and a CNC video about how I did the holes. Kudos to Peter Passuello of the CNCNutz youtube channel for the basics of how to CNC an 8 foot long board on a 4x2 machine.

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And finally, here's the video of the CNC process:

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Offline Whatsupdoc

  • Posts: 7
Re: New (CNCd) box beam workbench, with Festool holy system!
« Reply #1 on: January 23, 2017, 09:29 AM »
That is cool.  Thanks for sharing.
2 Kapex120, Ets125, RO125,Df700, Df500,ts75,ts55,Of1010,Ro90,Ras115,Dts400,Ct36,Ct26,SysLight,Cxs drill,Mft3,Lr32,FS800,FS1400,FS1900,FS2700,FS1400/2LR32,FS2424/2LR32

Offline leakyroof

  • Posts: 1958
Re: New (CNCd) box beam workbench, with Festool holy system!
« Reply #2 on: January 23, 2017, 10:01 AM »
I think the Green color improved it far more than the Box Beam construction..... [wink]
 all kidding aside, looks great and surely will provide you with superior clamping and assembly work down the road.
Not as many Sanders as PA Floor guy.....

Offline Kbuild

  • Posts: 3
Re: New (CNCd) box beam workbench, with Festool holy system!
« Reply #3 on: February 25, 2017, 09:26 PM »
I really like the green top! I almost ordered that for mine but chickened out at the last minute and went with graphite to match my cabinets in my shop. Are the holes chamfered at the top?