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How To Build an Assembly Table, Torsion Box Workbench – Woodworking

How To Build an Assembly Table, Torsion Box Workbench – Woodworking

Having a flat, sturdy work surface to build on will make your glue-ups and assemblies come out squarer than when working on a haphazard top. So, in this video, I built a Torsion Box assembly table to give me a flat surface from which to work. The top also doubles as a workbench in my small shop, with an end vise and set of dog holes to add additional work holding.

The overall bench is 48×96 and about 36″ tall.

If you want to build one, a full set of plans are available.

If you are interested in how I built it, watch the video below.

This assembly table features a torsion box top to give me a dead, flat, sturdy workbench.

A  woodworking vice and bench dog holes for a great work-holding experience.

Electrical outlets on each side allow quick access to power your tools when needed.

Flip-up mobile base to keep your work area flexible.

I have already used it on quite a few projects and love the large work surface, along with its flexibility to go from a workbench to an assembly table.

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The Build Process

Join me as I delve into the intricate process of building a torsion box-style table with unparalleled flatness and functionality.

1. Planning and Preparation

Before diving into the construction, I assessed my workspace, considering dimensions, workflow, and specific requirements with a clear vision.  I wanted the Torsion Box to double as an assembly table and a workbench.  I wanted it to be large enough to spread a project out on and assemble large furniture pieces on it.

2. Preparing the Plywood

To start the construction, I cut the plywood sheets to size and carefully ripped them using a table saw, making them more manageable for subsequent steps. Precision is key here, as any inaccuracies could compromise the integrity of the torsion box.

3. Establishing Parallelism

With the plywood strips cut, I focus on achieving perfect parallelism. Using a feather board set up, I joined one edge of each strip, ensuring they were straight and uniform.

4. Assembly of the Torsion Box

With attention to detail, I arrange the plywood strips in a grid pattern, alternating them strategically for added stability. Using spacers and glue, I secure the strips in place, ensuring they are flush with each other.

5. Reinforcing the Structure

To further enhance the strength and rigidity of the torsion box, I incorporate center supports and web pieces. Each component is carefully measured, cut, and assembled, to maintain structural integrity.

6. Integrating Electrical Outlets

I integrate electrical outlets into the design. This thoughtful addition provides convenient access to power tools, eliminating the need for cumbersome extension cords and enhancing workflow efficiency.

7. Installation of Workholding Features

No workbench is complete without adequate work-holding capabilities. I install a sturdy vice and drill dog holes into the tabletop, offering versatile clamping options for various woodworking tasks.

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8. Constructing the Base and Legs

With the tabletop nearing completion, I focus on crafting a robust base and legs. I fashion sturdy supports that securely anchor the table to the ground, even on uneven surfaces.

9. Incorporating Mobility Features

I integrate casters with a retractable mechanism into the base to enhance flexibility and maneuverability. This innovative design allows the table to move easily while remaining stable and secure during woodworking tasks.

10. Final Touches and Finishing

I focus on adding final touches and refinements with the major components assembled. I trim any excess material and sand surfaces for a smooth finish and apply protective coatings to enhance durability and aesthetics.

11. Testing and Evaluation

Before declaring the project complete, thorough testing is essential. I meticulously inspect every component, ensuring it meets my stringent standards for quality and functionality. Any issues are addressed promptly, guaranteeing a flawless final product.

12. Celebration and Utilization

With construction complete, I take a moment to celebrate the culmination of countless hours of craftsmanship and dedication. My new assembly table stands as a testament to my passion for woodworking, ready to inspire creativity and facilitate countless projects for years to come.

I’m the owner of Benham Design Concepts, a mixed media art studio where I design and build custom furniture and other works of art using wood, glass, stone, and various metals.
In this blog, I talk about the art I create, my journey, and the things I learn along the way.

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