Building the Paulk Workbench, Part 1 (Main Cuts & Sawhorses)

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After moving houses (and workshops) with my family 4 times since I started woodworking in 2012, I decided this time to design my shop with the concept of mobility. Whether I need to take the shop on site to help someone or to the next house/workshop if we ever move again I want this to go with me. Essentially, I want a “plug in and play” shop from now on. After lots of research, I found the Ron Paulk Workbench! This workbench was designed by Rob Paulk who has a ton of experience with contracting and woodworking, and his design represents his knowledge of both great utility and mobility. The two-part top allows it to fit in a van or a truck, and makes it easy to move around the shop or take on site. It’s also incredibly sturdy! I documented my entire build and I’m excited to bring you this comprehensive, instructional, multi-part video series on how to make it! I hope it helps you as you make your Paulk Workbench or a variation that fits your needs. Part 1 of this multi-video series focuses on the main cuts for the workbench/assembly table and how to make the saw horses. (You can learn more and download the plans on the Ron Paulk Website here: www.paulkhomes.com)
//Part 1 of this multi-video series focuses on the main cuts for the workbench/assembly table and how to make the saw horses.
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Details on this project below.👇🏼 For more projects, check out fieldtreasuredesigns.com/blog/
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////// MATERIALS USED
(1) 4’ x 8’ 1/2” Foam Insulation Panel
(5) 4’ × 8’, 1/2” Plywood
(1) 1 1/2” Polypro Webbing: amzn.to/2EfPNL9
#8 1/2” Panhead Screws
////// TOOLS USED
Bosch Circular Saw: amzn.to/2GJnPt3
Kreg Rup Cut Guide: amzn.to/2EgrhtC
4’ Level: amzn.to/2X78RCG
Stanley Powerlock Tape Measure: amzn.to/2IlJhGM
Milwaukee 4 1/2” Hole Saw: amzn.to/2Eh4RIx
Bosch 12v Jigsaw: amzn.to/2DThxUq
Random Orbital Sander: amzn.to/2SBg5My
Sanding Discs: amzn.to/2M98HWy
Bosch Router: amzn.to/2Efi84h
Bosch Colt Router: amzn.to/2GwachE
1/4” Roundover Router Bit: amzn.to/2EgQRyC
3/4" x 1-1/4" x 1/2"HSS Onsrud Spiral Bit: bit.ly/2GtXlfH
3/8" x 1-1/4" x 3/8" Carbide Onsrud Spiral Bit: bit.ly/2GtXlfH
1/2” to 3/8" Bushing Adapter: bit.ly/2EfB2bn
18v Bosch Drill/Driver: amzn.to/2SB1kth
12v Bosch Drill/Driver: amzn.to/2BWJHNl
Sliding Square: amzn.to/2Ef0mhv
///// PHOTO, VIDEO & EDITING I USED
Canon 80D: amzn.to/2VHhzab
Canon 10-18mm Wide Lens: amzn.to/2CNa2zh
Canon 50mm Lens: amzn.to/2COnzq8
Canon 18-55mm Lens: amzn.to/2Mepfwo
Rode Video Mic: amzn.to/2VIBR2V
iPhone X: amzn.to/2VrCf64
Tripod: amzn.to/2R9Qq12
iPhone Tripod Mount: amzn.to/2SzTd09
iMac: amzn.to/2VrstAJ
Recording to iPhone: amzn.to/2C0UshJ
Recording to computer: amzn.to/2BWNH0j

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Опубликовано:

17 фев 2019

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Комментарии : 133

@samuelstone5770 3 года назад

Thank you sir, well done. Really appreciate your time and how clearly you lay out the step by step without bogging it down with unnecessary details. Thoroughly enjoyable and informative!

@diywithandrew 3 года назад

Wow Samuel thank you for those kind words!

@danbachran2 5 лет назад

Great video. looking forward to part 2!

@diywithandrew 5 лет назад

Thanks, Daniel! Really appreciate that. Can't wait to get it to you!

@jeffcarmel5 4 года назад

Just a perfect vid !!!! Ron will be proud ;)

@diywithandrew 4 года назад

Thank you Jeff! That is very encouraging.

@healthfullivingify 4 года назад

Great job and great enthusiasm. I LOVE your technique of using a sacrificial foam insulation board between plywood of the table and one being cut.

@diywithandrew 4 года назад

Thank you Johnny! Yea it works really well. And can last for a long time too.

@billrayment1264 4 года назад

Liked the foam sheet idea too. Great safety idea if you need to cut 4 X 8 plywood smaller for use on a table saw in a small shop!!

@Nathan-H 4 года назад

Great video Very well presented and very easy to follow. Thank you for sharing this

@diywithandrew 4 года назад

Thank you!

@douglasrohman6191 4 года назад

Building one. Thanks for the video.

@diywithandrew 4 года назад

Awesome! Hope it goes well.

@TheWoodPastor 5 лет назад

Looks good bro! Love the sawhorses.

@diywithandrew 5 лет назад

Thanks Stephen! Can't wait to get into Part 2 when the total workbench comes alive.

@edharowicz9790 3 года назад

Preach on brown

@patrickdanna6363 4 года назад

Dude! This TOTALLY helped me build mine. Ron Video was okay, but you spent more time on some basics. Well done! Well done! Almost done with mine! Blythewood, SC!!!

@diywithandrew 4 года назад

Hey Patrick! Thanks so much for taking a minute to drop by and leave some positivity. So glad it helped. That is EXACTLY why I did this video. Congrats on almost being finished. Send me a pic! Go Tigers!

@TheSmartWoodshop 4 года назад

Nice Job!😎🤙

@diywithandrew 4 года назад

Thanks so much, Ron. As I'm sure you can tell, you've been a huge inspiration to me! I hope my videos do your design the credit it deserves. I also hope you are well during these crazy times.

@254JROCK 5 лет назад

Great 👍🏻 vid well done man

@diywithandrew 5 лет назад

254JROCK Thanks man!

@urwholefamilydied 3 года назад

DUDE!! as a backyard woodworker with a shitty table saw... that Kreg ripcut thing just blew my mind. I'm definitely buying that. Thanks for the tool i've never seen anyone use before. Crazy that's not a more common thing. (edit... just bought using the amazon link you provided. Hopefully that helps you out with a tiny little donation. Thanks again for the suggest).

@diywithandrew 3 года назад

Bro! Thanks so much for the kind words! Really appreciate you using my links as well to snag your purchases! Thanks again.

@adrianlouviere7650 4 месяца назад

Super! THANKS!

@diywithandrew 4 месяца назад

Thanks for watching!

@bpmunroe 4 года назад

Nice video. You should mention that cutting with a pattern bit does NOT give you the same copy as the template, because of the bearing insert that rides along the template edge. The cut is offset from the template, probably by. 1/16th on each side. Doesn’t matter here for saw horses, but does matter elsewhere. Here you ended up with 3 identical sides and 1 (the template) with a bigger opening in the middle. A flush trim router bit would work to give you an exact duplicate and can easily cut through 1/2” ply

@diywithandrew 4 года назад

Thanks Brian! Also great reminder! Thanks for sharing that knowledge with the community here. I think I forgot to mention it in this video since I wasn't too worried about the differential with my saw horses. I'm pretty sure I mention this factor in part two, since the variation is a little more important with the carcass spacers. As far as the flush trim router bit option (another great option), I had too many templates to cut (see part 2) so I opted for the more durable full spiral bit with the template collar instead of burning through flush bits. But it would have been worth comparing the cost of say 2/3 flush bits vs the one spiral bit because it still might have been cheaper! Thanks again for taking the time to post an insightful comment.

@ellenlee9390 2 года назад

Good advice

@diywithandrew 2 года назад

Thx!

@robertgullickson8758 4 года назад

Very well explained. Not too much “yada yada” bafflegab. Thank you

@diywithandrew 4 года назад

Thank you!

@SolarMillUSA 4 года назад

12:18 Not a sliding square, but a combination square 12:35 Not pan head screws, but truss washer head lath screws 13:38 Still a combination square, definitely not a speed square which is a totally different tool.

@cpusaf 4 года назад

Why be a troll? "Look at me everybody! I can point out when he used the wrong terminology for a tool! I'm awesome and oh so smart!" Try not to be a dick today.

@diywithandrew 4 года назад

Thanks bro. You just can't get away from them on the internet.

@diywithandrew 4 года назад

HAHAHA! Great reminder that I'm not perfect.

@svetlanagladkih4777 Год назад

thanks

@diywithandrew Год назад

You’re welcome!

@markgilder9990 4 года назад

You can get 4 parts for the saw horse bench stands. Cut out one pattern with a jigsaw and invert pattern to fit on board.

@diywithandrew 4 года назад

thanks for sharing great info!

@noahwoods9916 4 года назад

I love the application of the word "carcass"

@diywithandrew 4 года назад

haha! totally.

@stierhaushomestead 4 года назад

First off, great video...very helpful. Ron's plans don't really give a ton of detailed explanations. I'm new to using a router with a template, so this may be a total newb question. Did you account for the difference between your collar and bit when using it to but the other three saw horses and spreaders or was the difference not really important for this particular application?

@diywithandrew 4 года назад

Thanks man! Great question. For the saw horses, it didn't matter to me that one of them was slightly off than the others and for the spacers, I made one extra and saved the template so they would all be the same size with the cut out. Hope that helps!

@JonathanMcBane 4 года назад

I'm being serious, I really like yours shoes (two- toned brown) where did you get them or what are they called?

@diywithandrew 4 года назад

Heck yea! Thanks! LL Bean Boots. I LOVE them.

@mykalimba 3 года назад

Question about the first sawhorse panel that you built (the one used as the template for routing the others). Is that piece ever so slightly different from the other 3 pieces because of the bushing used in the router? Could you use a flush trim bit with an upper bearing to get a perfectly flush cut?

@diywithandrew 3 года назад

Yep. It is just a bit bigger but it didn’t bother me so I left it. Not even possible to tell when all finished. But yea I suppose that would work if you had the right bit and bearing.

@Argyll9846 4 года назад

Best workbench I've ever owned for catching sawdust. Looks good but not a patch on traditional benches.

@diywithandrew 4 года назад

I love mine!

@thejosuchav 4 года назад

I need a bench that will stay flat enough to make tables on. Some times even pour epoxy tables on it. Y'all think this is sturdy enough?

@cynthiaquilici6793 Год назад

Well, it seems like they serve different purposes. A traditional bench isn't portable.

@digitaldeskacademy 5 лет назад

How do i know what size upcut bit and bushing i should use?

@diywithandrew 5 лет назад

Great question! I've got the details in my notes above but I'll put them here as well. 3/4" x 1-1/4" x 1/2"HSS Onsrud Spiral Bit: bit.ly/2GtXlfH 3/8" x 1-1/4" x 3/8" Carbide Onsrud Spiral Bit: bit.ly/2GtXlfH 1/2” to 3/8" Bushing Adapter: bit.ly/2EfB2bn

@LongNguyen-go5rc 2 года назад

Great video! What type of plywood did you use if you don’t mind me asking?

@diywithandrew 2 года назад

Thank you, Long! Honestly I cannot remember. It was just your basic 1/2” sanded plywood from the big box hardware store called Menards at the time.

@thebandit1324 4 года назад

Hi how did you manage to cut the templates flush. The spiral bit looks smaller than the guide bush. So won’t there be an offset ?

@diywithandrew 4 года назад

There is a very small offset. Since the first was a template, the ones that I cut were all the same and I kept the template out of the project to save for if I build another one. Great question!

@annameer1767 4 года назад

I’m an absolute newbie... no pilot holes for the webbing screws?

@diywithandrew 4 года назад

Since they are so short, and I wanted them to grip into the wood there was no need. Great question!

@wakamiwailer 4 года назад

Doesn't using webbing for hinges on the top of the horses make them wobbly? I know Mr. Paulk must have been satisfied with how they function, otherwise he wouldn't put it in the plans but it looks like there'd be a decent amount of "slop." Could you use door hinges or something instead? Maybe with the table sitting on top makes them not move? But if they are only stable when used with this benchtop, it'd make them a one trick pony?

@diywithandrew 4 года назад

Not wobbly at all! This thing is so stable. Did you see me jump on it with my 200lb body at the end? Thanks for the comment!

@hyperborean. 3 года назад

Nice video. I just wonder why you used 1/2" plywood, instead of 3/4".

@diywithandrew 3 года назад

Thanks. Because it would be way too heavy and overkill to use 3/4. The goal is portability and the 1/2 is totally strong enough.

@hyperborean. 3 года назад

@@diywithandrew I see! Thanks.

@tdwoodworking4425 4 года назад

Where did you find the collar used at 8:35 for your router?

@diywithandrew 4 года назад

Great questions! Amazon. Here is the link.. amzn.to/341Reqo

@jakoj2098 4 года назад

Have u tried flush cut bit to be able to make template same size and use in build

@massivejester 9 месяцев назад

What type of plywood did you use? Looks like pine construction plywood but I might be off. Do you also have a link to it?

@diywithandrew 9 месяцев назад

It was just 1/2 inch plywood from Menards. I don't remember what grade it was exactly but it has held up extremely well!

@DMAbCD 3 года назад

Looks very much like the beginnings of a Han Solo Carbonite display.

@diywithandrew 3 года назад

Hahah!! You are so right.

@josephlebo7320 2 года назад

I’m going to be building the Paulk Smart Bench and I’m torn between 1/2 or 3/4” plywood. Are you still using this bench now? Did the 1/2” work out well enough or do you wish you would have gone with 3/4”? Thanks!

@diywithandrew 2 года назад

Awesome! After 3 years it is a staple in my shop. I’ve also moved it twice. I would definitely not do 3/4” mainly because I just don’t think for the size and weight you get any more benefit since for me the 1/2” has held up so well over the years. I’m actually planning a “Paulk Workbench After 3 Years” Video and this has reminded me to do it. Hope that helps and if you need anything else let me know!

@josephlebo7320 2 года назад

@@diywithandrew that’s great to hear! I’m thinking the 1/2” will be the way to go since I’ll have to have it standing up in a corner of my garage when not in use. Also, for the video I’d love it if you could go through any dog hole accessories/clamps/etc that do and do not work with the 1/2” thickness.

@diywithandrew 2 года назад

@@josephlebo7320 Yea man knowing you will need to move it around and stand it up I would definitely affirm the 1/2" choice. As far as the dog hole accessories, I will for sure add that to my video. Stay tuned and thanks again for the convo!

@josephlebo7320 2 года назад

@@diywithandrew update! I built the Smart Workbench and went with 3/4” for everything. It’s heavy but not too bad actually. I’m glad I did for stability and strength

@diywithandrew 2 года назад

@@josephlebo7320 Nice! Thanks for sharing.

@bobbobowsky8841 4 года назад

Z jakiej grubości płyty zrobiłeś blat ?

@diywithandrew 4 года назад

@dannichols6261 4 года назад

@@diywithandrew Google translate says he said, "What thickness did you make the countertop from". (Was Polish.)

@dannichols6261 4 года назад

@@diywithandrew This Polish *might* tell Bob that you used 1/2 inch thick plywood, and that you said so in your 'show more' section under the video (which also happens to be the same thickness in your 2nd video for making the top): Tuż pod filmem, jeśli klikniesz „Zobacz więcej”, w sekcji „UŻYWANE MATERIAŁY”, oznacza on, że sklejka, której użył, ma grubość 1/2 cala. I użył tej samej grubości w filmie numer dwa z tej serii, na górze.

@jakoj2098 4 года назад

hi may have missed it but what is that insulating material is it a high density foam or Styrofoam?

@diywithandrew 4 года назад

Great question! It is R-5 Rigid Pink Foam Board Insulation Sheathing available in many thicknesses and 4' x 8'.

@jakoj2098 4 года назад

Thanks looked it up here and the stuff we have here have bad chemicals that when cut and produce dust will be harmful

@ltandrepants 4 года назад

that’s a combo square

@diywithandrew 4 года назад

Lol. Thanks.

@sugarshane7601 5 лет назад

Nice hat go stros

@diywithandrew 5 лет назад

Yea dude... Astros!!

@ja60123 4 года назад

Reduce your rpms with a hole saw that large

@diywithandrew 4 года назад

Great call. Glad I didn't rip my arm off.

@SolarMillUSA 4 года назад

It's not just about control. Large diameters at high rpms mean there's a lot of SURFACE SPEED, and surface speed equals heat, which causes the bit to lose it's temper, which allows it to dull faster, which means more friction, which means the bit loses its temper even faster, which allows the bit to dull.... it's a vicious cycle.

@ja60123 4 года назад

Yes , surface speed. A hole saw can build heat burn the material and damage the tool quickly. Can even break the Arbor your drill chuck is mounted on. Careful use and a hole saw lasts for a considerably longer life

@TheToolnut 4 года назад

Also put a front handle on your drill, otherwise you run the risk of serious damage to your wrist.

@clmsnfan 5 лет назад

What part of South Carolina

@diywithandrew 5 лет назад

We were in Clemson. Go Tigers!

@clmsnfan 5 лет назад

@@diywithandrew awesome.. Hope you still are! I'm in anderson county and yes GO TIGERS!!!!

@diywithandrew 5 лет назад

We actually moved last summer. But we really enjoyed living there!

@tostacey1 3 года назад

Nice vid but a bit aggressive on the volume control

@diywithandrew 3 года назад

I’m going to release a voice only version soon. Do you think that’s a good idea?

@tostacey1 3 года назад

@@diywithandrew awesome idea keep up the great vids👍

@diywithandrew 3 года назад

@@tostacey1 Thank you!!

@pepperman9 4 года назад

Two words. Table saw.

@diywithandrew 4 года назад

Um.. Yes

@drreason2927 4 года назад

I built my Paulk bench a couple years ago and find it an invaluable part of my daily work whether in the shop or on the job! I can't believe I survived so many years without it!!

@diywithandrew 4 года назад

Heck yea!

@berndheiden7630 4 года назад

Now don‘t be offended, this is a serious question. I have always wondered why you would build the sawhorses, there are reasonably priced sturdy metal ones out, adjustable in hight. I‘m using those and nothing rocks. The Ron Paulk‘s design of the horses look far less rigid to me. And with 2 sheets of plywood they are probably not even cheaper, are they?

@diywithandrew 4 года назад

No offensive at all! Fair question. In terms of cost, I do think two sheets of plywood is cheaper than a good set of horses. I like the idea of the work bench sliding onto the cutouts in the plywood horses. All I can say is that it has worked VERY well and I'm over a year into having it. I was just standing on it yesterday to reach something and no shake or wobble at all. If you have good horses, I think you could skip that step. Maybe its just the look of consistency? Anyhow thanks for commenting!

@berndheiden7630 4 года назад

Field Treasure Designs Thanks for the experience, I only had the look and if it works it works! Greetings from Mallorca.

@diywithandrew 4 года назад

@@berndheiden7630 Thank you! greetings as well. Beautiful place! Can I come visit?!

@berndheiden7630 4 года назад

Field Treasure Designs Any time when you visit the beautiful island!

@agimasoschandir 2 года назад

One thing I noticed in the Paulk illustrations was a framing square leaning on one of the legs suggesting that one cold store it there, so making your own they can be customized

@giantsfan1925 4 года назад

why do you move so much?

@diywithandrew 4 года назад

Life circumstances, I guess.

@bryan7567 4 года назад

Your audio track needs work bro. When you talk it's s good volume, but as soon as you stop talking your music comes on way too loud. Cheers

@diywithandrew 4 года назад

Thanks for the feedback.

@terrigelbaum8066 4 года назад

Your poor wife.....tell me you're not going to move again ...for at least a couple of weeks....

@diywithandrew 4 года назад

Haha! She is a champ. But yes, we are actually moving to Denver in 3 weeks! Crazy.

@TheToolnut 4 года назад

The man is always the prize, not the woman, Mgtow.

@twochaudiomg2578 4 года назад

fast talker

@diywithandrew 4 года назад

Yep! Life is short. :)

@007more7 4 года назад

This guy just wants here himself talk....

@diywithandrew 4 года назад

lol. "here"

@keithfoster6000 4 года назад

Who needs to know what you do in your life, very wasteful

@diywithandrew 4 года назад

What was wasteful was the two seconds I spent typing this reply.

@jasonpluis3493 4 года назад

Perhaps because it explains why he is building a teardown bench rather than a more standard workbench?

@Reallythough21 4 года назад

Keith Foster theres always one peckerhead in the crowd🤷‍♂️🤦‍♂️.... keep it moving hero...... On a side note very good job breaking it down for those who are new to carpentry in a way they can understand. And even a better job holding yourself accountable to answer to each and every question put your way!!! You just got a new subscriber!! Keep up the good work brother 👊

@diywithandrew 4 года назад

@@Reallythough21 Thank you!!

@diywithandrew 4 года назад

@@jasonpluis3493 Thank you for your insight. So glad it might have been helpful!

@robertgullickson8758 4 года назад

Very well explained. Not too much “yada yada” bafflegab. Thank you

@diywithandrew 4 года назад

Thank you!