Dan,
I scaled down both benches I made mostly for transport reasons. Getting an 8' bench into my basement wasn't going to be fun with the stairs I have either. I also like the fact that when I am ripping down 8' sheet goods, I have room at the ends of the 7' table for the guide rail clamps to hang down if I need to use them.
Re. the MDO Ply... I chose that because of availability and because I wanted as smooth a top as possible. It is obviously more costly, but worth it to me.
I don't know the weight of either unit, but the smaller one is very light. My wife carried this unit out of our basement and set it up on her own as an extra table for a party we had and commented on how light it was. I also made the stands for the smaller unit out of 1/2'' ply rather than the spec'd 3/4'' ply. For the smaller table I think it is adequate, but for the larger table, I would go with the spec'd 3/4'' for the stands and bottom shelf. Setting it up is quite easy if you simply put your arms through the box beam and hold it out in front of you horizontally... I haven't tipped over yet
The side openings on my tables are smaller... 4'' I think, rather than the 5'' specified. I assumed the 4'' on the first I made and wanted the second table to match. I haven't found it limiting what or how I put things inside the table, but I do think 5'' is a better dimension.... that is one thing I would change on version 3.0 for me. Also, I used a compass to layout all my round cutouts and then cut a template with the jigsaw. I don't have a 5'' hole saw... I think I would spend the money and get a 5'' bit if I were to do it over.
I did use 3/4'' holes in the top, drilled with a forstner bit. The holes were located from measurements taken on each side, and then I just put a + where each x and y axis intersected. I didn't want to simply use long lines or chalk lines and their associated intersections because of the marks left on the top. This is quite accurate, but a plunge router on a guide rail would be more accurate, and with an accurate layout, could be used for guide rail placement with dogs. I wanted the holes for clamping only. The 3/4'' holes are quite tight for the Festool Clamping Elements, so I would recommend using a 20mm bit when you drill/route the holes.... just gives you more clamping options. I think that is it as far as lessons learned/do overs. Oh yeah.... 1/16'' roundover bit is perfect for easing all edges!
The leaf blower in the picture was for cleaning the dog off before he was allowed back in the house. You'd think the noise of a router would deter him from "helping" but he insists on being right there! Good luck with the bench!
Nate
