The Last Workbench You'll Ever Need

[@yojoehd]

I have built several flat surfaces to use as assembly tables. One aspect that needs to be considered in building a torsion box, not mentioned in videos, is that you need to have, as close as possible, a flat and level surface to work, clamp, glue, and assemble the torsion box. It becomes the standard for flatness and level. Otherwise you will glue a permanent cup, bow, or twist into the torsion box. Ideally, the torsion boxes rigid construction should rock on any uneven or non level surface. I really like that you placed levelers at the base of your legs. My machine tool background proclivities and working with granite precision flats always forces me to lean toward extreme precision. Your video is great.

[@CoffeyCustomBuilds]

Thank you!

[@getdirecti0ns]

Ideally you start as flat as you possibly can and then surface the dried assembly on a cnc, both sides then coat or laminate the face to add stability

[@yojoehd]

@@getdirecti0ns Even if one does use a CNC with laser accuracy to flatten both sides, the placement of a finish would have to take place and be of equal porosity on both the bottom and top faces. I can only imagine the beautifully flattened torsion box being twisted out of shape by the application of finishing moisture. I am giving some consideration of using aluminum extrusions for the internal frame of any torsion boxes that I build in the future.

[@Notjay95]

I built one for my work. I surfaced the vacuum table then cut the bottom on the cnc. I used dados and rabbets and assembled it in place. It’s 5x10 and only has ribs going the 5’ direction spaced 2’ apart but it’s dead flat and is still holding up great. I laminated the top and leveled the base/attached it to the floor with tapcons.

[@tomherrick2043]

Nice design and build. Before I got into restoration and cabinet work I spent 20 years in mapping. Nice to see flat files incorporated into the shop.

[@getdirecti0ns]

Nice work, one tip I will share is when ripping a lot of long strips from sheet goods it is easier to rip several larger strips first then rip the final strips from those. This not only makes them easier to handle than a full sheet but you maintain straighter cuts. Just calculate the rough width pieces to account for blade kerf loss plus a little margin like 1/4”

[@CoffeyCustomBuilds]

Definitely the best way to do it.

[@Rainman270]

Nice job. I made a torsion box runoff table using Ian Kirby's article in Fine Woodworking ( ? Around '82 ). I used 3/4x1x3 pine for the perimeter and 1/4 plywood for the grids for lightness, along with glue and staples. I put about 4 cinder blocks on the top and bottom skins when I glued them to the grid then trimmed the overhang with a router. I then applied Formica on all four sides then trimmed that. The only thing I wished I did different was glue two strips of would in the box where I routed the guide for the miter/cross cut sled.

[@CoffeyCustomBuilds]

Sounds like a great build!

[@XPLRNW]

I just wanted to stop what I was doing and tell you that I think you did such a great job on this dead flat surface... no joke... Very nice job! I'm glad that I took the time to watch and learn from your video. Thanks so much for sharing! Keep up the great content my friend... Fellow KZbinr from Northwest Washington. pnwfullstop

[@CoffeyCustomBuilds]

I really appreciate the kind words. Thanks for watching!

[@markadamarnold]

That thing WILL NOT blow away in a stiff wind! Great work.

[@CoffeyCustomBuilds]

No sir! It is crazy heavy!

[@guillermopalmisano8957]

It’s crazy to see how much your shop has grown in a year! And now your full time! Love that outfeed table

[@CoffeyCustomBuilds]

I can't even believe it man.

[@kevinbaxter1571]

love you show the Product FIRST! nice job man

[@CoffeyCustomBuilds]

Thank you

[@ComandanteJ]

That's the largest crosscut sled i've seen, and seems pretty lovely to use with that rail for accesories and even some dust collection. Awesome project, If i ever have a workshop large enough to fit a table saw AND an outfeed table, i'll probably go with this design, hehe.

[@CoffeyCustomBuilds]

I really appreciate it! Thank you and I love this sled!

[@edreusser4741]

I wonder if it might have been simpler to use the long pieces with slots instead of cutting small pieces. Just cut a 3/4 in slot halfway thru the width and then connect it all together. You definitely deserve a subscription and a thumbs up for this superb work. Thank you for your excellent craftsmanship!

[@CoffeyCustomBuilds]

Probably would have been honestly.

[@CLove511]

I'm not sure, but it feels like sixes either way. You either spend the time assembling and clamping and gluing, or cutting out a million half-laps but then assembly is a breeze.

[@rogerkblake1]

The video came out great!! Thanks for sharing

[@CoffeyCustomBuilds]

Thank you! I'm really glad you enjoyed it!

[@StefOutside]

Looks great bud. The video was informative and straight to the point. Keep up the great work!

[@CoffeyCustomBuilds]

I appreciate the kind words!

[@CReevesMakes]

Wow, that thing is solid! I like the process and use bracing! Nice work man!👍🏻

[@CoffeyCustomBuilds]

You could park a truck on it! And it's like DEAD flat!

[@ZacBuilds]

Heck ya man, those dovetails in the table top are super smart. Don't think I've seen anyone do that before. I, for one, would've been happy to see all 56 cuts haha.

[@CoffeyCustomBuilds]

😂 no you wouldn't have! Snooze fest man!

[@Matasky2010]

Dovetails? Those are just dadoes that allow his miter gauges to slide further

[@EternalHarvestDecor]

Very cool my friend! Great video

[@CoffeyCustomBuilds]

Thank you! I'm finally happy with the audio. Just need to adjust the music up next time.

[@TyeMadeIt]

Dude, this is my favorite video yet! Everything was spot on! Happy to help you and thanks for the shout out! Loved the humor in there too. Oh, you don't want to watch me drill 56 pocket holes. Lmao

[@CoffeyCustomBuilds]

😂 I can see retention dropping there haha thank you bro!

[@scottswoodcraft1026]

Really nice build Mike!

[@CoffeyCustomBuilds]

Thank you, Scott!

[@sloaneswoodworking8674]

Another great video man! That is a beast! It'll be a sweet addition to the shop

[@CoffeyCustomBuilds]

Thank you my man! I'm very happy with the table and the video!

[@jbbhight]

Nice job. I learned a lot. One thing I have yet to find, though: some engineering calcs on how wide the grid pieces should be. I believe this was 3". Why not 2" or 1.75"? Yours must be an extremely rigid box -- yet would knocking 1" or 1.25" off the width (or height as the case may be) of the grid have resulted in something less rigid?

[@CoffeyCustomBuilds]

I think you'd get the same rigidity as long as you're over a half inch.

[@randallthomas5207]

The rigidity is definitely effected by the depth of the box. The analysis would get pretty complex. But basically it is a square of the depth. But the strength of the glue joints would eventaully come into play, as well as the tensile strength of the sheet goods.

[@jbbhight]

I just built three 4' x 16" with 1 1/16" wide pine ribs (3/4 wide) for my van camper, and they flex less than 1/8" w/250 pounds in the center; no noticeable flexing with two people sleeping or sitting. It'd be interesting to come up with some engineering specs for these applications. @@randallthomas5207

[@anthonyvincent9990]

loved the build and love the beard.

[@CoffeyCustomBuilds]

thank you

[@BuiltKnotBought]

Great video Mike looks way flatter then my current workbench

[@CoffeyCustomBuilds]

Thanks bro. It's nice to know I can trust it's flatness.

[@MartyOfAllTrades]

Looks great my dude. Good job

[@CoffeyCustomBuilds]

Thank you sir! It's been a really great add to the shop.

[@BruceAUlrich]

Great video, Mike! Enjoyed seeing the process. You'll get a TON of use out of that thing.

[@CoffeyCustomBuilds]

Thank you, Bruce! I freaking love this table. It's already a huge add.

[@FredMcIntyre]

Awesome work Mike! 😃👍🏻👊🏻

[@CoffeyCustomBuilds]

👊🏼🤘🏼🤗 thanks, Fred!

[@AndyBirdBuilds]

Good stuff man! That thing is stout!

[@CoffeyCustomBuilds]

Thicc! I love this thing!

[@MrHghoang]

That thing looks solid man, great video!

[@CoffeyCustomBuilds]

Thank you my friend! Which part do you hate most? 😂

[@CharacterRedWorkshop]

Awesome build dude! That turned out perfect. Your new shop is really coming together nicely!

[@CoffeyCustomBuilds]

Thank you! I love my new shop!

[@pepper7144]

I am about to build an outfeed/assembly table. Is there a reason not to use half-lap joints to do the basic assembly of the 'field' members. The pocket hole screws are a prefect fit to reduce the glue needed.

[@CoffeyCustomBuilds]

Half laps are a perfectly viable way of doing it. I went back and forth multiple times.

[@pepper7144]

@@CoffeyCustomBuilds thank you for your quick response to an old thread. The half laps would need to be very near prefect but could all be cut with the same setup. This method would be so much easier than the nail and glue hundreds of pieces needed for a 4 by 8 ft table. I will be using for multiple tasks. Thanks again.

[@eitantal726]

How does the torsion box help? How is it better than, say, a solid core of some kind?

[@CoffeyCustomBuilds]

Depends on what your needs are. But because the ribs are cut to the same height you get a very flat surface.

[@eitantal726]

@@CoffeyCustomBuilds because they're the same height, you get to copy whatever's underneath. It won't make it flat, it would make it parallel

[@DesignCraftWorkshop]

Awesome build man! Great video too 👌🏻

[@CoffeyCustomBuilds]

Thank you! I need to get my cinematography on your level.

[@hardworkcreative738]

Is a torsion box very good for hand tool working? I ask because, aren’t they light in terms of workbenches?

[@christiansapp856]

Nice work mike!!!! This seems like a beast of a table. A little sad I didn’t get to watch all 56 parts!

[@CoffeyCustomBuilds]

😂 I'll edit and send you a video of it.

[@RescuedWoodCo]

Mike, such an awesome video!! I’ll definitely watch it a few more times when I get ready for my outfeed!

[@CoffeyCustomBuilds]

Thanks man! It came out great. This thing is a monster!

[@lambcurry7709]

I was really hoping that u will show how do u making the top flat seems like you really just rely on ur original build table to be flat to begin with.. what happen if you don’t have a flat surface to start with?

[@CoffeyCustomBuilds]

You are relying on the ribs being cut the same thickness throughout. The top and bottom is being attached to that.

[@IntoTheWildernessWeGo]

Such a great build Mike! That things gonna last forever!💪

[@CoffeyCustomBuilds]

Thank you bro! So much to get better at but I'm happy with this!

[@Beefypvp]

Hey great vid but I don't understand how you ensured it was dead flat. I see how it's of uniform thickness but did you do anything to ensure the box overall isn't slightly curved over a large area? High quality plywood?

[@CoffeyCustomBuilds]

Yes. Like I said in the video, the mesh frame in between the sheets on top and bottom is EXACTLY the same thickness. So when everything is attached to the mesh frame, everything because exactly the same thickness throughout. I also show an 8' straight edge laying across the whole thing and I did this at multiple different directions and sides. Couldn't even get a sheet of paper under any point of the straight edge. Thanks for watching!

[@TheMadJester159]

@@CoffeyCustomBuilds that doesnt ensure flatness. A torsion box has to be built on a flat and level surface to ensure flatness. Watch Mike Farrington or The Wood Whisperer on this subject

[@b-radg916]

@@CoffeyCustomBuilds: Don’t know how you kept from making the pieces slightly differing thicknesses when you sanded the top of the grid?

[@blairm3504]

If you really want to split hairs, you could measure inconsistencies down to the molecular level and still make the claim that it's not "dead flat." However, that would be incredibly pedantic. Levels of precision are dependent upon what is needed for the design application. In this case, for this application, the term "dead flat" is more than appropriate - unless you want to be incredibly obtuse.

[@Beefypvp]

​@@blairm3504it's unclear if or why this design is dead flat but the video describes the table as being so, and viewers like myself may have come here seeking this. The desirability and practicality of degrees of flatness is separate issue

[@robertkrueger3902]

Wow am I too late for the party? 3 years lol One question is it super important to have a dead flat place to assemble the torsion box. I am looking to re do my MFT style table and doing it in a torsion box construction..

[@CoffeyCustomBuilds]

Depends on what you're going to assemble on it I'd say.

[@yojoehd]

If one is to build something flat you must have a flat reference. The reference points can be gained using a laser or an accurate level. Otherwise you will build twist or work into the torsion box. I just recently posted a similar question.

[@randallthomas5207]

Re MDF soaking up glue: Apply a glue cut 50% with water the day before and let it seal the edges.

[@CoffeyCustomBuilds]

Definitely something I've learned since doing this. Good info to get out there for sure.

[@MG-qk8tx]

Can you reference where you got the leveling feet & maybe the mfg's name & model? Thanks.

[@CoffeyCustomBuilds]

Sorry for the delay! Here they are: amzn.to/42P7Vng

[@ericyocom7932]

Great video, Mike! I think a better option would have been to count the 56 pocket holes like the Count from Sesame Street. Haha. Kinda not fair that we don’t get to suffer through that arduous process...right? Perfectly flat surfaces are so necessary in a shop. I’m definitely interested in making one of these for myself, so thanks for making me realize it’s not as complicated as it seems. Can’t wait for the next one!

[@CoffeyCustomBuilds]

Thank you! Hahaha huge missed opportunity! I would recommend making one. They aren't incredibly expensive and a perfectly flat surface, like you alluded to, are invaluable.

[@dirtybaywoodshop-joeporter5650]

Great video, Mike! I'll soon be building a new workbench/assembly table and I'm thinking 5x5 would be a good size since I can get Baltic birch in those dimensions (and I also don't have room for a 4x8). My current workbench is the BMW based on Steve Ramsey's design from Woodworking for Mere Mortals. It's definitely great to have, but I've wished many times that I had something bigger during the last few projects. I'm considering the idea of a torsion box, and it seemed a bit overwhelming, but after this video, I'm pretty sure it wouldn't be too bad. Looking forward to more videos. New sub!

[@CoffeyCustomBuilds]

Thank you and you'll be super happy with the 5x5. It has so much space on it. It's really a pleasure to have in the shop.

[@jaykepley5238]

Nice job! 🖖

[@CoffeyCustomBuilds]

Thank you, Jay! Glad you liked it!

[@JustinMoritz]

Thanks yes - I have never head of this style

[@CoffeyCustomBuilds]

Cool

[@curgonthebandit]

What is the tool they use to drill at the angles at 3:09? And what is it used it? New to woodworking.

[@CoffeyCustomBuilds]

That is a pocket hole jig. It's for making pocket holes.

[@George_designs]

Where’d you get that pocket hole jig?

[@CoffeyCustomBuilds]

Here's the link: amzn.to/3lCEIGA

[@eitantal726]

What is the purpose of screws if the glue is applied?

[@CoffeyCustomBuilds]

Just to use as clamps

[@michelevitarelli]

Great project and video. What kind of glue do you use?

[@CoffeyCustomBuilds]

Thank you very much. I use Titebond 3 on everything.

[@AtticBuilds]

I love the video and the table don't get me wrong. But scratch my itch for simplicity, could you achieve the same result with less material / work or does it make a difference in flatness?

[@CoffeyCustomBuilds]

You can definitely make a flat surface with 3/4" plywood and some joints. But it WILL sag over time without this super grouped up grid. It just will. You can do a Ron Paulk style torsion box for sure that is cheaper. However, this wasn't very expensive. It's more expensive than a sheet over some joists but it will be dead flat for the life of it.

[@AtticBuilds]

@@CoffeyCustomBuilds Ok, now it makes more sense with the over time bit. Thank you for your answer.

[@CoffeyCustomBuilds]

Happy to answer! This cost around $200 and I don't think I'll ever have to replace it. Well worth it. Also, since it's dead flat I can use it for other things as well.

[@AtticBuilds]

@@CoffeyCustomBuilds Yeah it is well worth it. I came from reddit but now you have a new subscriber 👍

[@CoffeyCustomBuilds]

Oh man thank you so much! I hope I can make videos you enjoy! I'll do my best!

[@cgpimp1]

Can someone tell me what the notches on the outfeed table are for? I have an idea just want to confirm

[@CoffeyCustomBuilds]

The two parallel ones?

[@cgpimp1]

@@CoffeyCustomBuilds yes sir

[@cgpimp1]

Is it for a large cross cut slide ?

[@CoffeyCustomBuilds]

Yessir! It's for the crosscut sled.

[@WhiteLabWorkshop]

That looks like a really tedious process, but it sounds like it’s worth it. I wonder, would plywood have done a better job not slurping up all the glue?

[@CoffeyCustomBuilds]

Plywood would have definitely soaked up less glue. However, it wasn't such an issue that it wasn't worth the effort. Also, I wanted MDF because it's heavier. I wanted to make this as heavy as I could. I didn't want it moving. Ever. Also, it wasn't nearly as tedious as it looks and it was definitely worth it. I love my outfeed.

[@WhiteLabWorkshop]

Cool. Thanks for the reply!

[@CoffeyCustomBuilds]

Thank you for watching!

[@Poolboy28560]

Torsion box engineering question: You used the "long piece-short piece" method. others use the interlocking dado slot method. Wouldn't the interlocking slot method create a more rigid (better?) result?

[@CoffeyCustomBuilds]

Yes and no. It would for the assembly but the actual structure is held together by wood glue which is than MDF and even wood itself. So in actuality the joint is stronger with wood than it would be with interlocked half laps. It's not going to make it any weaker because you'd still glue those but you're adding in a factor that can go wrong. If you don't get the half laps exactly right your piece is no longer flat.

[@difflocktwo]

All (most) of the load is taken by the skin. you could fill the core with styrofoam instead of a wood grid and get similar results. Stressed skin structures are amazing. Modern cheap furniture is made of basically air and a little bit of paper.

[@AlesEveryday]

Very nice!!! New sub, hope to see more vids

[@CoffeyCustomBuilds]

Awesome! Thank you so much for the support! Planning 3-4 a month.

[@pTreesWorkshop]

That table looks solid AF brother! Nice work! However, I feel like I missed out on some solid drilling and cutting action. lol Fine! Keep all the good stuff to yourself ;-)

[@CoffeyCustomBuilds]

I'll make you a montage 😂

[@pTreesWorkshop]

Coffey Custom Builds he’ll yeah! No music, soft light, soft voiceover please. Trying to add to my ASMR collection

[@CoffeyCustomBuilds]

pTree's Work Shop Slow mo pocket holes drilling.

[@victorscasas1193]

What are the benefits of this one?

[@CoffeyCustomBuilds]

Benefits of the torsion box table?

[@victorscasas1193]

@@CoffeyCustomBuilds Yes. As opposed to a regular top.

[@CoffeyCustomBuilds]

@@victorscasas1193 did you watch the video? I explain that.

[@victorscasas1193]

@@CoffeyCustomBuilds of course I watched. Seen most of your videos but I thought there were more than just "super flat". Looking for ideas to make my first assembly table.

[@mkngjoy]

Random question - you mentioned "Plywood" a bunch of times in the voiceover - but in the video, it looks like 1" MDF. was it a mix of the two?

[@CoffeyCustomBuilds]

That top and bottom sandwich pieces are 3/4" 5'x5' Baltic birch plywood. The middle torsion frame is 3/4" MDF.

[@ChrisHaggertyArt]

Dope. Now fly here and give me a hand with mine. 🤝

[@CoffeyCustomBuilds]

That would be a ton of fun! It only took a weekend!

[@ChrisHaggertyArt]

@@CoffeyCustomBuilds it would be a blast haha

[@SomeDudeOnline]

One thing I don't understand about torsion boxes is how mounting them to something that isn't dead flat doesn't cause anything to flex and therefore make the top surface not deadflat.

[@CoffeyCustomBuilds]

Good luck flexing a torsion box. The plywood will absolutely bend to the shape of the box.

[@SomeDudeOnline]

@@CoffeyCustomBuilds I guess it’s just a matter of how much force on one corner it’ll take to flex the box and whether or not the anchor point can withstand that force?

[@CoffeyCustomBuilds]

@SomeDudeOnline have you made one?

[@SomeDudeOnline]

@@CoffeyCustomBuilds I have not. Been thinking about it but I’m cheap and I just don’t know enough about them so my biggest concern is that I put it together and bolt it to my bench (replacing my current top) and the bolts through off the flat-ness.

[@CoffeyCustomBuilds]

@SomeDudeOnline I've made about 10 in the past few years. I have always been impressed.

[@luke_fabis]

Man, carpenters have a very different definition of flat compared to machinists.

[@CoffeyCustomBuilds]

Yes I believe that is a known fact.

[@Creator_Nater]

Good yob

[@CoffeyCustomBuilds]

Thank you!

[@barnettbuilds227]

Dead nuts flat.

[@CoffeyCustomBuilds]

I have a lot of trust issues but I can trust how flat this is!

[@barnettbuilds227]

@@CoffeyCustomBuilds that's great! It never occurred to me to do this with mdf. I'm going to bre building one soon because I brought home a Laguna F1 today. Woot woot! I instantly regret wooting, I blame the saw excitement.

[@CoffeyCustomBuilds]

Congratulations dude! That's awesome!

[@TheMadJester159]

A true torsion box has to be built on a flat and level surface to ensure flatness. Saw horses, boards, and shims can accomplish this.

[@CoffeyCustomBuilds]

If you'd have watched the whole video you'd see that this had leveler feet attached. It is a true torsion box and is perfectly level and perfectly flat.

[@howisitnotavailable3]

#FirstLike #FirstComment #FreeMikey

[@CoffeyCustomBuilds]

🙌🏼 we need to get an apartment together

[@ronaustin7090]

N

[@CoffeyCustomBuilds]

O

[@mitchblackmore5230]

Dude, it's a workbench, not a machinist's surface plate.

[@CoffeyCustomBuilds]

I build custom furniture. I need a flat surface.