Big Bench Build 

As a carpenter I learn so much from you. I’ve built your smart bench, cross cut jig, and router table. You’ve taught me crown. So I’m in. But as I recently started rewatching your earliest videos, you have gained serious video skills also. You can start a new channel teaching about the world of production when you’re looking for something new.😂

There's something to keep in mind. You're showing people (often newbies like me) how to build a smart bench with another smart bench & accessories they likely won't own. As such, you might reach and attract more buyers for your plans with a demonstration video building your benches old school by starting out as they would with the minimum tools necessary. They'll have to buy the parf guides, obviously (which is expensive enough on top of all the plywood), but we can watch videos of people building far more complicated and labor intensive things with just the basics. They'll have some kind of circular saw, for example, but they won't likely have a track/plunge saw with parallel guides (TSO or otherwise). They certainly won't have your crosscut guide or a miter station of any kind. They'll be lucky if they have a miter saw. Most will also be coming to the table with a small router only (if they're lucky to have that). I'm just a diy homeowner with an older house in need of fixing/renovating. I am intrigued by your plans because, as you've stated in another video, your benches are great for those working out of a garage because of the modularity of the design (my wife and I want to park our cars inside at night). I for one would like to see an old school build video. I'm not talking about hand saws only, but I think a lot of diyers, myself included, don't even have a table saw. I'm on the Dewalt Flexvolt platform and have their circular saw, miter saw (like yours) & factory stand, small plunge router, random orbital sander, oscillating multi tool, angle grinder, hammer drill & impact driver, jigsaw and a few pneumatic nailers of various brands. I also have a Sawzall and some other hand tools as well as some flimsy saw horses, but that's about it. I'd say I'm off to a fairly good start toolwise, and I plan on picking up a track saw and TSO parallel guides at some point (in lieu of a table saw because I'm not doing this for a living), but I was hoping to build my bench first (before getting the track saw & guides). Anyway, like I said, it's just something to keep in mind since you might increase your sales of your wonderful plans. As it is now I've seen some other people build your benches and they look kinda shoddy if you ask me. I'm starting to lose my confidence. :( I know I will figure it out. But I imagine you'd capture more market share for those even less confident than I am.

Ron - this is the best build video you’ve done yet ✅ I built my PSB in the summer and it took me a couple of weeks to get my head around the offsets & patterns; now you’ve shown the final piece of the puzzle I know for sure it will help other beginners really get to grips with the system. It’s the largest/most challenging thing I’ve ever made and despite lots of mistakes and frustrations along the way (mostly from my inexperience), the minute I first tentatively placed the bench down on the saw horses...let go and nervously stepped back to see it was still standing up was awesome! 😱👍 Thank you for all your content this year - I know that it has kept me sane & focused whilst the rest of the world seemingly went crazy. In spite of everything going on I can look forward to 2021 and a long list of projects to work through, almost all of which will be either creating components for or directly using your PSB bench & the impressive collection of additions you’ve developed. Whilst my Wife & most certainly my wallet! (😱) are perhaps not your biggest fans...I and I’m sure hundreds of other people, are genuinely grateful for the time and effort you’ve put in to videos like this and the channel as a whole. Wishing you a happy Christmas 🎄 and all the best for the New Year! John

I'm on about my sixth time watching this video. It seems like every time I want to build these benches, the price of ply skyrockets. Some day.

Thanks for going over the pattern bits again 😊

Ron. A tip for accurate holes. I tried printing a hole template on paper with center marks for the holes 1:1 scale. I made a bench by plotting all holes on a large format paper and sticking it down to the ply. Poor mans cnc, (a plotter). You get a very precise mark for the holes that you can just prick through the paper. No measuring, just align the paper with the edge of the ply. I tried double sided tape and tested with spray glue, both work fine. A print shop can plot black and white template very cheaply. Luckily I have a plotter at my office so it was free for me. Any CAD program can be used to draw a template of holes, you can also get creative with hole spacing and patterns.

It would be great if you had a closer camera shot too show us the tools and materials your using.

The modularity of your designs is incredible

Excellent Video 👍. I always learn so much from your videos.

That’s the first time I noticed you using the dog holes of your PSB to actually guide you cross cuts. Thanks for including that.

I have 40 minutes to spare today, I'm going to go build one of these. :) Awesome job as usual Ron.

Fastcap has a new flat metric/standard tape i think you would really enjoy for layout. I used mine for the first time yesterday and would definitely recommend it for any shop !

Very good history lesson on the hole spacing. Thank you for that, Ron!

Ron, when are you going to sell a life size pattern so us novice fellas can make a solid bench?! I’d def pay for it.

Excellent work!

Awesome, Ron!!

I’d be interested in seeing your total tool list for this in the description. I’m familiar with things like the PARF guides, Starrett square, Festool and TSO products but it would be interesting to see some of tools like drill and router bits, etc.

I think what I would do is have the edges of the top and bottom panels where the 2 halves butt into each other a 32nd long. That way there would be no gap between the 2 halves. After both were assembled and connected I'd then layout and drill the 20mm holes. Maybe add some dominos, (no glue), or some other method for precise alignment when they're reassembled.

Bit wobbely during the routing making the temporary jig to create the master jig no matter how shallow the initial and final cuts are. Why not simply screw a scrap bit in the middle just big enough for the router base to ride on and by this provide support on both sides of the cut, no matter how the router is rotated(rectangular shaped router base) to get an even cleaner cut and demands less balancing and focus during the actual cut. Recommended especially when cutting in expensive materials, for example when routing for an insert plate to make a router table. Chip outs far too common when almost finalizing the cut.

Ron - Would you please provide info on the toggle-style dog clamps used in this build video? Thanks again for another great video and bench. I continue to learn a lot from each video.

I think I'm going to try and build this using the Shaper Origin!

Hi Ron have you thought of offsetting your holes and have an isometric pattern between your 96 centre pattern as well? To save weight and give you 30 60 90 and 45 degree cuts

Hi, Ron! Another thoughtful video! Question...what's the router bit cutting length or depth of the cut on the router bit when you're patterning out the templates here? Based on the thickness of 2 pieces of 18mm ply I'm assuming one needs at least a 1 1/2" cutting length on the Spiral Upcut bit, correct? Sorry, if you already explained this in the video.

Great video Ron. I noticed your shop heater. I have a Mr. Heater propane, though it does not market at a 100% "indoor" unit, so wondering how you go about that. I crack the door and that's good enough, but wondering your experience. Would you feel comfortable with stain, I have not, but keep wondering what the capabilities are if I wanted to stain?

I just bought a HUGE CNC machine with a work surface of 1500mmx1500mm. I'm going to be looking over your various plans to see which one will serve me best, even if I have to make multiple builds and attach them the way you did in this build.

Looks awesome ,but no glue bot from fast cap

As you use the UJK parf guide rulers why aren.t you using them to layout all the screw holes as well? seems like a no brainer.

Is the next gen table going to have triangles?

Ron, quick question, just bought the PSBB plans, do the sawhorses store inside for transit? Ill be storing these flat side by side (as they would be on the horses) in my van. Sorry if you've answered this elsewhere. Thanks

Do the two halves consistently and precisely realign when joined together to create a precision cutting station? I’ve a single MFT style top which has an error of only 0.002” per 12” when using bench dogs for fence/guide rail alignment but am considering this top as my shop is in the basement and these could be easily hauled up to the garage for breaking down sheets rather than hauling them into the basement. That said, I’ve doubts how well the guide rail will align when using a hole from each half but maybe these consistently realign perfectly every time?

Hi Ron. Bought the plans, but already busy thinking about modifications. I'm building this as an outdoors worktable which will not be transported, so I'm thinking of ditching the 2 part torsion box top and just making it a single piece. I also don't care about tool storage in the torsion box, so I'm thinking I'd cut a ton of 4 inch holes in the underside to reduce weight. I also might just mount on an existing steel table frame I have so not need the sawhorses, but haven't decided on that. Have you done/seen builds using a one-part torsion box? Must be harder to keep the parf system accurate matching two pieces together perfectly with zero gap. Lastly, what would you use for an outdoor finish? thx, and nice work!

Ron I notice in previous videos you were using pocket hole screws why the change?

Is the dimension for the placement of the first screw through the long edge of the top & bottom shown on the plan? I'm guessing it's 25mm, but can't seem to find it written anywhere on plan. Old eyes missing something? Please help me satisfy my curiosity. Thank you.

I can't find or have overlooked why the outermost two rows of parf holes are spaced closer. I'm ready to drill my tops now, but would like to understand the functionality of this before I start plunging holes.

A well thought out product - quick question, what kind of plywood are you using?

To get. CNC service quote what is the hole spacing I should request on the 2400mm lent sheet

I have a question sorry if it’s already been answered. I was wondering if you finish these tables and if you do what do you recommend.

Have you thought of making one piece top design?

Going to attempt to build this but in a much smaller 2'x6' platform and was wondering if anyone has attempted to use folding table legs from a 2x8 table. Would be super easy and i think would be stable.

How difficult would it be for a novice to do this? I really like the idea of having modular workbenches (and other tools like router tables, crosscut, and TS holder but not sure if I have the skill and precision that it would take. Thanks.

Now I have the UJK Parf Guide system I’m ready to build the Instead of just throwing out my old bench I thought I’d just In my case I’ll wait till I can get a set of the smart

Do you sell a CNC files for you benches?

Purchased. Still a big fan. I've been missing the hours and hours of that instructions and comments voice from my days building the Paulk Smart Bench. I made mine from cheap ply at the time. Are you still using the 18mm Baltic Birch B/C grade?

Can you teach me to work that fast?

Ron, great video. I was wondering what you were using for the portable drill guide on the backside of the top for preventing chip out. It was a blue drill attachment and was that used with the the parf 20mm drill or a different drill bit?

Overall height??? As built based on plans... overall height of the big bench PLUS smart kart when wheels are down? Anyone know?

I think I found a typo worth about $10 in your PSBB plans. The key calls for "(2) 2-Pack TSO Speed Knob[s]" but in the materials list (right next to it) it lists "(1) 2-Pack TSO Speed Knob[s]". Do you need one (1) or two (2) "2-Pack" packages of "Speed Knobs"? I assume it is just supposed to be one (one for each end of the two tables you're combining), but you know what they say about "a.s.s.u.m.e."

What do you think of putting veneer on the tables want to order your tables but would like to put on a veneer when I grow up do glue UPS

Ron - I would appreciate your advice on router bits. If you were just starting to buy router bits and a bushing set, would you go with metric or imperial? I have both metric and imperial collets for my router.

did you change your microphone?

So, this looks interesting. Other than less weight, I'm a bit puzzled about all the holes -- what are the Top 5 (10???) uses for all these holes?

Lovely 😍💋 💝💖❤️

Oh yeah. Do you love me? 😍💋 💝💖❤️