Hello all: I wanted to make a few comments about work benches in general. These are things I've learned over the years.
My present work bench is made of a solid core door as the top. The support is a trestle structure with stretchers between the trestles near the floor. The actual work surface is Formica. The edges of the work surface are banded in oak. I use both an end and side vise. I have bench dog holes in the forward third of the top. I did build a tool well; but, soon discovered this was a mistake. It is nothing more than a place for saw dust to collect and a great way to pinch a finger when sliding a board across the top. The metal magnetic trays work much better for keeping those small parts all in one place. Under the work surface, I have a cabinet or tool chest for my rasps, chisel's, sanders... A bench should be: absolutely flat smooth durable work surface strong heavy sturdy have the means of holding the work piece securely be comfortable to work at Have room for your toes under the bench all the way around A work bench is probably the most customized tool in the shop. The top should be at the correct height for the craftsman. I built mine such that when standing at the bench, the palms of my hands rest on the surface with out any bend in my back or my elbows. I'm pretty short about 5:6; so, would n't work for you taller fellows. A good friend of mine is about 6:5. When I'm at his shop, I have to stand on something to be comfortable working. I get a lot of good natured bantering from him about that one. Other considerations about height depend on what is being built. If I had the room, I would actually have 3 benches. Large work requires a much shorter bench like below knee level. (tables, dressers, chairs) Smaller work requires a higher work surface say about belly button height for jewelry boxes and craft pieces. as it is now, I have to get on the floor with those bigger projects. There are numerous vises and fixtures out there to equip a bench. One needs to chose what works for them. Be careful to not turn your bench into an assembly table so you don't limit the usefulness of the bench. I have found that a side and end vise with bench dogs do all I need. However, some might like the tee track instead. My experience with this is that it gets stopped up with saw dust though. This doesn't happen with the bench dog holes. It is extremely important to have a work surface that is slick and smooth. And, that can be wiped off easily. Since, I used Formica, I can just pop off those glue beads when they dry. Also, the finish or stain just wipe up. Everything else comes up with a scraper. I heard it said that a serious wood worker will build 3 benches in his or her life time. This is my second; so, I've got one more chance to get it right. I will keep my new bench just about the same. I will use poplar for the trestles and stretchers instead of pine. The top will be made out of hard maple instead of a door and Formica. I will keep the same dimensions and vise locations. I will absolutely, in no way, build another tool well. I was sliding a heavy chest across my bench and pinched my ring finger on my right hand. That one brought tears to my eyes. I lost the nail. There was some choise words spoken as I recall. I will also make round corners instead of sharp 90 degree ones. My bench has lasted about 13 years and has served me well. When I do retire it, it will be like letting an old friend go. We've built many projects together. I know where every thing is stored, I can reach for a vise handle and know where it is, I can walk around the bench with out thinking about it. However, I know I'm a better wood worker than I was 13 years ago and can do a much better job this time. Terry
