This is what I did.... Updated 1/23 w/pics

[rjwz28]

So I've been reading up on torsion box tables and how good they are for doing projects with a dead flat top, so I made one this weekend. I copied the design and steps from David Marks and built one with 1/2" mdf top and bottom. Size is 42" x 72". It is now done, nice and flat ready to use, but..... It is fricken heavy, without even legs. It's got to be over a hundred lbs. I built it without legs on purpose as to store it against the wall of my garage as this is how I work. I move everything to the sides to park the 2 cars in when I'm not woodworking. When I do projects, I take the cars out and set up all my machines and put them back when I'm done for the weekend.

So I built this table with the intentions of leaving it on the side wall and setting it up maybe with folding legs or something when I want to use it, but it is so heavy that I can't carry it onto legs or horses by myself!

So does anyone out there have an idea how I can make something so I can move (roll) it on the side vertically against or on a wall when not in use and be able to set it up when I want to by myself?

Any ideas would be appreciated.

Thanks,
Rob

1/22/12
This is what I did. I got this idea on the net from  workbenchmagazine.com. It is called a panel moving shuttle made to transport sheets like plywood putting them on the table saw or a table. They include plans with dimensions. I modified it to work with my table. It is a neat idea and if you go to the site it even has a video to show you how it works. If I knew how, I would attach the video for you to see. I can now set up, move around and take down the table just by myself. Thanks to all for your ideas. Thanks for looking.

All the material was ¾” plywood. I also made 2 folding sawhorses specifically for the height of the table. There are 2 cross braces with notches to hold the handles together when I am moving the table around and also for when it is standing temporarily before I place the 2 saw horses under it. The wheels are 6” lawnmower wheels I got from Home Depot.

Photo 1.
This is how I will store the table when not it use. I have it folded up and against the side of my garage with the 2 cross braces and a 1” pipe for a temporary leg. Takes up about 8” of space.

Photo 2.
I fold out the handles and attach the 2 cross braces to make it more stable so I can move it around easily without the handles moving all over.

Photo 3.
I pull the handles toward me and let it balance on the bottom with the wheels. It will stay in this position by itself without tipping over either way. When I want to move it, I just lift up a little to get it off the floor and onto the wheels.

Photo 4.
Next I bring the back of the table up to level and use the 1” pipe to hold it in place temporarily. It doesn’t rock because the 2 handles have flat spots before the end to keep it steady enough.

Photo 5.
Now I place the sawhorses underneath both ends.

Photo 6.
This is how it looks after I fold up the handles, remove the pipe and put the horses exactly where I want them.

If anyone has any questions on the build just let me know.

Aloha,
Rob

 

[AlexThePalex]

Well, for starters, you shouldn't have built it out of MDF. MDF is a lot heavier than plywood.

 

[Guy Ashley]

Here you go!!!

THE ULTIMATE WORKBENCH

Very strong and stable, flat and light!

 

[mattfc]

How about somthing like this, since you want it stored on its side to minimise width, but this should make it easy enough effort wise to flip to the horizontal, put some fold out legs on the corner to stabilise.. sorry very quick crappy sketch

 

[GhostFist]

interesting,matt

 

[mattfc]

Otherway would be to have 2 sliding tracks like this
http://www.ironmongerydirect.co.uk/Products/Sliding_Door_Hardware/Sliding_Door_Systems/12746/Straightaway_100_Sliding_Door_Gear_Fittings/345152

the track is 3m long, two tracks would could support 200kg.. have the track run perpendicular to wall you want to store it on running up to the wall. Connect two davits to the table, two blocks and tackle and lift and slide. You get the blocks with ratchet mechanisms.. I would have thought the table is light enough to be able to faily easily angle down onto some tressels. Rather than pull it to the side, you could just hoist up onto the garage roof, and use 4 davits.. thread the blocks a bit like this

you would want to loop the rope and use double pulley blcoks though to half the lifting force required

 

[richard.selwyn]

Don't know it it would be feasable, but you could cut the top in two and then install a simple means to join the two haves together.
(I have 4 cheap torsion boxes that are about 8 x 4, so I can carry then but have cut one down the middle to make it more versatile. As they are made out of cheap hardboard, I put a sheet of ply on top.)
Richard

 

[rjwz28]

How about somthing like this, since you want it stored on its side to minimise width, but this should make it easy enough effort wise to flip to the horizontal, put some fold out legs on the corner to stabilise.. sorry very quick crappy sketch

This looks like a good idea. I'm probably going to make something like that. I need to figure out how to make the pivot part on the table then how to attach the legs.

Thank You,
Rob

 

[mattfc]

This looks like a good idea. I'm probably going to make something like that. I need to figure out how to make the pivot part on the table then how to attach the legs.

Thank You,
Rob

If you can live with it only folding down one way, I would just buy a heavy duty hinge used for gates.. e.g. this sort or thing, bolt the long bit on the upright, the plaet on the underside of the torsion box

Else if you were to do it like I have shown, cut a D shap out of 1" ply and use a 1/2" bolt that goes through the D and the upright to form the pivot point. Use some strong metal all brackets and glue to fix the D shape to the underside of the torsion box

 

[davee]

Cut it in half - two smaller torsion boxes might be more flexible than a single large one.  Might not fit your work flow, but just a thought.

 

[rjwz28]

This looks like a good idea. I'm probably going to make something like that. I need to figure out how to make the pivot part on the table then how to attach the legs.

Thank You,
Rob

If you can live with it only folding down one way, I would just buy a heavy duty hinge used for gates.. e.g. this sort or thing, bolt the long bit on the upright, the plaet on the underside of the torsion box

Else if you were to do it like I have shown, cut a D shap out of 1" ply and use a 1/2" bolt that goes through the D and the upright to form the pivot point. Use some strong metal all brackets and glue to fix the D shape to the underside of the torsion box

I need another sketch Matt.

Rob

 

[spikfot]

Well, for starters, you shouldn't have built it out of MDF. MDF is a lot heavier than plywood.

I'm sure if you're willing to loan the OPer your time machine, that comment will be of some use.

 

[Guy Ashley]

Well, for starters, you shouldn't have built it out of MDF. MDF is a lot heavier than plywood.

I'm sure if you're willing to loan the OPer your time machine, that comment will be of some use.

;D ;D ;D

Oh Man, that is SO funny, and I thought only the Brits were that sarcastic!!!! [not worthy] [not worthy]

 

[Rob Z]

Hi Rob.        Maybe you could install a cleat on the wall which is slightly below the bottom of the table top.  Once you then roll the table into position, the top could be pivoted up against the wall and secured in some way. Mouch of the weight of the top would be supported by the cleat while you pivot it upwards. 

 

[rjwz28]

Well, for starters, you shouldn't have built it out of MDF. MDF is a lot heavier than plywood.

I'm sure if you're willing to loan the OPer your time machine, that comment will be of some use.

Ha ha ha.  I thought that was pretty funny myself William. It's funny how people like to give their ideas about what I should have done.  It's done already.  I'm looking for a solution in the present term.

And I built it like that because several people have made them with the same material that I did and I didn't hear anything about the weight or I may have changed some things. Also, I don't think 1/2" ply would be as flat as mdf and if I am correct on that then that would defeat the purpose of the whole table.

I thank all of you who've gave me an idea.

Rob

 

[peter halle]

Is it fair to assume that your skins to the torsion box are glued on in addition to any other fastening?

Peter

 

[spikfot]

According to industry standards, variances of up to 3/32", or 2.4mm are acceptable in plywood. Not good.
I can't stand working w/ MDF- the stuff gives me hives, but in this case I'd go with it.

 

[rjwz28]

Is it fair to assume that your skins to the torsion box are glued on in addition to any other fastening?

Peter

Yep, Titebond 3 and finish brad nailer.

Rob

 

[peter halle]

OK.  Here is an idea that could reduce weight depending on how closely you spaced the ribs.  On the underside if you can locate the ribs, using a jigsaw or a hole saw or drills bits, you could remove material in the vacant areas.  You could also use Matt's sketches and instead of having the pivot point mid way front to back, move the pivot to the rear more taking into account you ultimate work surface height and then only add 2 front legs and use what Matt drew as the rear legs.

You could also drill the top with a hole pattern like an MFT if you have voids in the bottom to get rid of sawdust.

Peter

 

[jmbfestool]

Well, for starters, you shouldn't have built it out of MDF. MDF is a lot heavier than plywood.

I'm sure if you're willing to loan the OPer your time machine, that comment will be of some use.

Ha ha ha.  I thought that was pretty funny myself William. It's funny how people like to give their ideas about what I should have done.  It's done already.  I'm looking for a solution in the present term.

And I built it like that because several people have made them with the same material that I did and I didn't hear anything about the weight or I may have changed some things. Also, I don't think 1/2" ply would be as flat as mdf and if I am correct on that then that would defeat the purpose of the whole table.

I thank all of you who've gave me an idea.

Rob

.  

Good Quality ply is completely fine and is flat enough.   Problem with MDF healtwise is worse than plywood

I think his pivot table is a good solution to your problem.  Like Pete said you can alter the position of the pivot but this only makes the table heavier to lift up and down having the pivot closer to the centre or in the middle keeps it lighter to rotate.