Author Topic: DIY MFT / Paulk Bench Build  (Read 119180 times)

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Offline JayStPeter

  • Posts: 399
DIY MFT / Paulk Bench Build
« on: March 05, 2013, 10:25 PM »
Hey guys, have not been actively posting for several years, but have been lurking around.  My shop has been used heavily at times and sometimes gathering cobwebs.

I've been planning some garage storage and figure it's time to upgrade my plywood cutting setup a bit.  This first post will mostly be a bit of what I currently have, why I want to change it, and my plan.  But, the cutting has started.

First up, my current plywood cutting table.  I made it back when I got my ATF55.  It's about 40"x6'.  There's a 3/4" plywood grid using some pretty heavy duty banquet table legs I pulled from a dumpster.  I eventually covered the top with a piece of 1/4" ply so I could use it for an occasional assembly table and it has pretty much been setup constantly since.  It is covered in glue and paint.  But, it doesn't work great for much other than quick sizing plywood due to the lightish duty construction.  I use a piece of 2" foam on it (yeah, they were out of the good kind when I bought that piece).  I like the foam underneath as it really helps dust collection of the saw.  So, I'll probably continue to use that in a slightly different way.



I also have a MFT1080, but I find it much too small.  I find that by the time the pieces get small enough to process on it I can just use my table saw.  The MFT usually stays setup also, but acts as junk collection.  The shop is also pretty crowded with both tables setup.  My goal is to eliminate one of them and maintain the functionality of both (including the junk collection point).

After some looking around, I liked the Paulk Ultimate bench design.  Looks good since I already have a main workbench.  The lower part can act as junk collection and the top will be heavier duty than the cutting table and a bigger MFT.  I don't really need the jobsite portability though and expect it to be permanently setup.  But, not at 4'x8'.  I decided I would build it in two pieces like the Paulk design, but have the main/permanent half at around 32"x6' and the other half at 16"x6'.  I'll make the base expandable so I can remove the 16" portion unless I'm processing plywood.  I bought the plans from Mr. Paulk, so I'm not going to go into the details of that part of the build.  But, you can see the top and bottom pieces cut on the table above and here are the blanks for the rest on my workbench.  I may add some sort of extensions to support 8' also, but haven't really needed that on the current setup.  Should be pretty easy to add if I need it later.



The top will have an MFT functionality.  I plan have the ability to mount a 55" rail for crosscutting and have a fence with a tape measure built in for cuts up to 48".  I'll probably modify Mr. Paulks fence design, but I'm planning on it being similar.

I'm going to use the Festool hole pattern by using an old MFT top as a template.  This one got water damaged when my dishwasher leaked into the basement shop.  It's been used as a template before, but this time I'm going to first try it with a 20mm Forstner bit and a cheap drill guide.  It might go a little faster than the drill a smaller hole and pattern rout it to 20mm method.  The template top has been in a closet leaned against a wall for a few years now, so I'm using my mortiser to try and take the wall lean bend out of it.



My plan for the base is something like the outfeed table I built a few years ago.  I used 2x8s for each side and ripped them for the "legs" and strechers.  Then just glued the whole thing into a rectangle (square in the case of the outfeed table).  I plan to double the side stretchers and make an oversize duplicate of the back so it will slide out and take the table extension.  Otherwise, the table extension will probably take a shelf of my wood rack.



Another improvement in plywood processing is a new 118" rail.  That way I don't have to keep connecting and disconnecting my two 1400s.  I wasn't really thinking how big that sucker really is.  For some foolish reason I was expecting to hang it on one of my 9' walls.  Duh.  So, I took the crate and screwed it to the ceiling to get it out of the way.  Worked out pretty well, I think that's permanent.



That's all I have for now.  Will update as I progress.
« Last Edit: March 05, 2013, 10:29 PM by JayStPeter »
Jay St. Peter

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Offline MrToolJunkie

  • Posts: 2982
Re: DIY MFT / Paulk Bench Build
« Reply #1 on: March 05, 2013, 10:37 PM »
Love the idea of screwing the crate to the ceiling for the rail...I have mine in my lumber rack and it is a hassle to take it down.  Great idea.  Looking forward to seeing and reading about your new set-up.

Scot

Offline JayStPeter

  • Posts: 399
Re: DIY MFT / Paulk Bench Build
« Reply #2 on: March 08, 2013, 11:02 PM »
Swiss Plywood

Jay St. Peter

Re: DIY MFT / Paulk Bench Build
« Reply #3 on: March 09, 2013, 12:44 AM »
Great shop, very organized. Looks like table is coming along swell, are you confident holes are perfectly aligned?

Offline JayStPeter

  • Posts: 399
Re: DIY MFT / Paulk Bench Build
« Reply #4 on: March 09, 2013, 08:15 PM »
Great shop, very organized. Looks like table is coming along swell, are you confident holes are perfectly aligned?

Thanks, just did a deep clean of the shop.  Hauled away a truckload of scrap.  It's nice to have it usable again.  Fairly confident in the hole alignment.  Used a MFT top as a template.  If I ever rebuild this I'll use MDF for the top though.  The standard hardwood ply I used chipped out a bit on the B side and really took some effort to get it nice to use.


A little more progress today.  Both of the top modules are dry fit.  Still have to open up the access holes in the sides, but getting close on gluing up the top modules.

Jay St. Peter

Offline john stevens

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  • Ardmore, PA
Re: DIY MFT / Paulk Bench Build
« Reply #5 on: March 09, 2013, 11:09 PM »
Hi Jay.  Didn't notice this thread before tonight, great to see you posting again.  Thanks for sharing this project here, looking forward to seeing more.

Best regards,

John
What this world needs is a good retreat.
--Captain Beefheart

Offline JayStPeter

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Re: DIY MFT / Paulk Bench Build
« Reply #6 on: March 10, 2013, 06:32 PM »
Thanks John.
Jay St. Peter

Offline bmwproboi05

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Re: DIY MFT / Paulk Bench Build
« Reply #7 on: March 11, 2013, 09:13 PM »
looks good. Cannot wait till you are finish. Been needing to make a new work bench.

Offline JayStPeter

  • Posts: 399
Re: DIY MFT / Paulk Bench Build
« Reply #8 on: March 17, 2013, 07:18 PM »
I figured I would easily finish the two modules today.  But, nope.  This thing is taking longer than I expected.

I did get the small module glued up.  Some rounding over of edges and sanding and it's done.



The large module failed final dry fit.  Very odd as I have fit it several times previously.  I'll have to rework the dadoes in one side to make it right.  After the glueup of the small module, I'm thinking I will screw the whole thing together then remove the screws and plug the holes.  I used every clamp I had on the small one and I still had to put a few screws through the top to get it tight in the center.

Jay St. Peter

Re: DIY MFT / Paulk Bench Build
« Reply #9 on: March 17, 2013, 08:17 PM »
Project is looking great. Shop is looking a little messy though. Just joking,mine never looks that good.

Offline TinyTiger

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Re: DIY MFT / Paulk Bench Build
« Reply #10 on: March 17, 2013, 09:24 PM »
Nice job!  I'm really looking forward to seeing the rest of the build.  I have a set of banquet legs in the basement that need a good project home.  You may have inspired me............hmmmm......... [scratch chin]
Russ

Offline JayStPeter

  • Posts: 399
Re: DIY MFT / Paulk Bench Build
« Reply #11 on: March 18, 2013, 01:34 PM »
Project is looking great. Shop is looking a little messy though. Just joking,mine never looks that good.

Ha, it  just had it's every 10 year deep cleaning.  I'm surprised how cleanish it is every time I walk in.  I actually found a place for almost everything.  But, being glaring white, the sawdust does tend to get washed out.

Here's a camera angle that might make you feel a little better.  The back bench contains all the stuff that still needs a home  ::)  A month ago, the whole shop looked like this, but with scrap piled on every surface and in every corner.



Jay St. Peter

Offline Alan m

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Re: DIY MFT / Paulk Bench Build
« Reply #12 on: March 18, 2013, 07:11 PM »
dont feel too bad.
my shop was a discrase about 6 months ago. stuff eveywhere. i dumped anything that was truely rubish .
i built 10 cabinets for the walls and put everything into them. i rearanged the shop and gained about 8 foot square in the middle that i could use to actually do some work
"A pessimist sees the difficulty in every opportunity; an optimist sees the opportunity in every difficulty."
- Sir Winston Churchill (1874-1965)

Offline Alan m

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Re: DIY MFT / Paulk Bench Build
« Reply #13 on: March 18, 2013, 07:13 PM »
i also thnk that the key to a clean shop is to put everthing away before you leave.
every time i go into the shop i put away at least 10 things.
i can honestly say that everything that has a place is in its place. there are things awaiting a place thow
"A pessimist sees the difficulty in every opportunity; an optimist sees the opportunity in every difficulty."
- Sir Winston Churchill (1874-1965)

Offline Greg Powers

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Re: DIY MFT / Paulk Bench Build
« Reply #14 on: March 18, 2013, 08:28 PM »
That is a nice size work space.  [smile]
Greg Powers
Size:XL

Offline JayStPeter

  • Posts: 399
Re: DIY MFT / Paulk Bench Build
« Reply #15 on: March 18, 2013, 09:48 PM »
That is a nice size work space.  [smile]

Thanks Greg.  Being 'L' shaped it's not as efficient as I'd like, but I definitely don't need any more space.

i also thnk that the key to a clean shop is to put everthing away before you leave.
every time i go into the shop i put away at least 10 things.
i can honestly say that everything that has a place is in its place. there are things awaiting a place thow

That's the plan.  We'll see how long it lasts  [big grin]
Jay St. Peter

Offline sprior

  • Posts: 452
Re: DIY MFT / Paulk Bench Build
« Reply #16 on: March 18, 2013, 09:50 PM »
My current theory on a clean workshop is to have a specific place for every tool so you can see what's not back in place and to minimize the amount of horizontal non-task surfaces to collect clutter.  The workbench in the picture is my main clutter collector (clean at the moment), but I got rid of the bigger table that was in that spot for the smaller bench.  My main work table can't collect clutter for long because I cut up sheets of plywood on it so it HAS to be clear.
« Last Edit: March 18, 2013, 09:52 PM by sprior »

Offline JayStPeter

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Re: DIY MFT / Paulk Bench Build
« Reply #17 on: March 19, 2013, 12:14 AM »
My current theory on a clean workshop is to have a specific place for every tool so you can see what's not back in place and to minimize the amount of horizontal non-task surfaces to collect clutter.  The workbench in the picture is my main clutter collector (clean at the moment), but I got rid of the bigger table that was in that spot for the smaller bench.  My main work table can't collect clutter for long because I cut up sheets of plywood on it so it HAS to be clear.

Flag on the play, I count exactly 2 scraps in that shop.  Disqualified for non-hording tendencies.  ;D

Good on you if you can keep your shop that organized, looks great.  I need a spot for every tool so I can identify what my teenage sons have wandered off with to fix their skateboards.
Jay St. Peter

Offline sprior

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Re: DIY MFT / Paulk Bench Build
« Reply #18 on: March 19, 2013, 12:20 AM »
Here's a picture of my rolling plywood and lumber rack.  And I certainly do have hoarding tendencies, I've got pieces of wood and plywood that are a few inches by a few inches.  However I've also got a wood burning insert in the fireplace and a couple of burn buckets in the shop - my projects give me a warm feeling either way.

Offline sakurama

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Re: DIY MFT / Paulk Bench Build
« Reply #19 on: March 19, 2013, 02:22 AM »
My current theory on a clean workshop is to have a specific place for every tool so you can see what's not back in place and to minimize the amount of horizontal non-task surfaces to collect clutter.

Okay, I'll bite. How'd you do the cut outs? CNC would make sense but I fear it might be by hand. [crying]

Gregor
new york • portland • www.gregorhalenda.com

Offline sprior

  • Posts: 452
Re: DIY MFT / Paulk Bench Build
« Reply #20 on: March 19, 2013, 08:15 AM »
Not nearly as bad as you might think:

1) trace out the tools on a wide board.
2) route the horizontal finger grooves.
3) using a jigsaw cut out the traced tools all the way through the board.
4) glue another board behind the first.
5) add triangles on the sides and mount on the wall.

Offline Peter Halle

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Re: DIY MFT / Paulk Bench Build
« Reply #21 on: March 19, 2013, 09:18 AM »
Great execution.  Strangely I was considering doing that same approach with some twists in my shop.   [thumbs up] to you.

Peter

Offline Tinker

  • Posts: 3782
Re: DIY MFT / Paulk Bench Build
« Reply #22 on: March 19, 2013, 09:39 AM »
My current theory on a clean workshop is to have a specific place for every tool so you can see what's not back in place and to minimize the amount of horizontal non-task surfaces to collect clutter.  The workbench in the picture is my main clutter collector (clean at the moment), but I got rid of the bigger table that was in that spot for the smaller bench.  My main work table can't collect clutter for long because I cut up sheets of plywood on it so it HAS to be clear.

Yeah Steve.
I have warned my wife that your shop is definitely OFF LIMITS [ban]
I have also given YOU fair warning [dead horse]
Tinker
Wayne H. Tinker

Offline sprior

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Re: DIY MFT / Paulk Bench Build
« Reply #23 on: March 19, 2013, 11:23 AM »
Thanks Peter.  When I took electronics in high school the lab had tool holders like that and I always thought it was a great idea.  Then when I finally got a suitable shop space I was able to implement it.

Tinker,  You're totally wrong in the way you're approaching this.  Your wife lets you spend all that money on Festool toys and I think you've got tools that it would be dangerous for you to attempt to find.  You should bring her over and say "see, I could have my shop this neat too, I just need to spend..."  With the size of your shop you need to be more organized than I am to make it work.  And don't give me that nonsense about your basement being so small - you're the guy with access to a backhoe...   [tongue]

Re: DIY MFT / Paulk Bench Build
« Reply #24 on: March 20, 2013, 12:30 AM »
My current theory on a clean workshop is to have a specific place for every tool so you can see what's not back in place and to minimize the amount of horizontal non-task surfaces to collect clutter.  The workbench in the picture is my main clutter collector (clean at the moment), but I got rid of the bigger table that was in that spot for the smaller bench.  My main work table can't collect clutter for long because I cut up sheets of plywood on it so it HAS to be clear.
I'm really jealous of how nice everything looks. So I was zooming in the pic trying to pick something apart. Scanning for any little flaw I could find.....came up with nothing.      Being honest hurts sometimes.  Love what you've done

Offline sprior

  • Posts: 452
Re: DIY MFT / Paulk Bench Build
« Reply #25 on: March 20, 2013, 12:41 AM »
I'll give you a minor one for free - the tool holders are built as I get new tools or just get around to organizing ones, so sometimes the grouping isn't what I would have chosen if I did everything at once - I've got tape measures in three different places.  This doesn't really matter to me because I know where everything is, but if someone came into the shop they might wonder why similar things aren't always together.

Offline Tinker

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Re: DIY MFT / Paulk Bench Build
« Reply #26 on: March 21, 2013, 12:18 PM »
Steve, just now getting back since Monday.  I hope you did not take my last remark about "off limits" seriously.

To everybody else who is following this conversation, Steve gave a very serious reply to my not so serious remark.
And, just in case anybody is wondering about the exchange, he is DEAD ON CORRECT.  If you have looked at his pics above, They do not do full justice to how neat and well organized his shop is. 

If anybody would want to see an exact opposite, mine wood be a 180º opposite.  As Rodney Dangerfield might say, 'It is so bad that last week I went down there to find a router.  I couldn't find the router, but it took me three days to find my way out of there.'

Steve, you do have a great and well thought out shop setup.

BTW:  I was starting work on a cab for under my CMS (in between a couple of other projects with my LS biz) when I remembered the Festool Connect.  Tuned in to a really fine presentation by Mr. Sedgewick.  Wish i could have made it.  Incidently, Peter Halle looked great on camera after the demo. :)
Tinker
Wayne H. Tinker

Offline sprior

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Re: DIY MFT / Paulk Bench Build
« Reply #27 on: March 21, 2013, 12:26 PM »
I gave a serious answer because there was a point to be made and I couldn't resist poking back a little, but that doesn't mean I took your light hearted post very seriously.  You've got a LOT of money's worth of great tools buried under there and Festool type organization is about your only shot at making a space that size really work well.

Offline JayStPeter

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Re: DIY MFT / Paulk Bench Build
« Reply #28 on: March 21, 2013, 11:44 PM »
After some head scratching I've finally gotten my large module dry fit.  Turns out the problem was the way I clamped my router jig on the larger parts.  I used different clamps on all the smaller parts, so they worked great.  On the larger parts, I got lazy and only got down one large clamp.  So, my jig was slightly skewed by the clamp pulling on one side.  Error doubled with the mirror image and some things didn't fit right.  I'm not sure why they seemed to fit on earlier dry fits.  But, technique adjusted.  Dadoes filled and rerouted and here it is dry fit.



I actually used my smaller module to rework a side that was a little off due to the skewed cuts.  Got a chance to play with the height a bit.  Still not sure how high I want this one.  Tall is good for a lot of operations, but slightly lower probably best for using it as a cutting table.  I'm thinking I can put the small module on top of the large one for router work.

Jay St. Peter

Offline sprior

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Re: DIY MFT / Paulk Bench Build
« Reply #29 on: March 22, 2013, 12:54 AM »
Looks really nice JayStPeter!