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So, a few weeks ago I asked about various ideas for shooting benches; and I got a lot of feedback, most of which weren't exactly what I was looking for, so I went out and designed my own.
It's essentially the same as the booger bench really, though I used full length doublers, and a single cutout.
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Excuse the shadowed pics, the daylight was so bright it was washing out on the bare wood.
Also, since I was building for both myself, and for a friend who drives a Camry, we went a little shorter; and that let us use some plywood left over from a previous project.
Basically all it takes is about 1/3 sheet of plywood (the top is 1/4 sheet, but you need doublers for the table legs), figure on being able to make 2 from 1 sheet of plywood, with quite a bit left over. You could in theory build it with jsut 1/4 sheet, but hoenstly, plywood is relatively cheap, and the cost differen between 1/2 and 1/4 sheet isn't going to be big enough to make it worth the trouble, or the slight compromise in strength in using short doublers to save plywood.
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We built them 24” wide and 36” long to easily fit into a car trunk. I used 3/4” hardwood A/B ply, a set of Waddell legs, and a bunch of 1-1/4” galvanzied deck screws.
The bench top is two rip cuts for dimension, then a slot cut for the bench cutout (I built it with a single side cutout), six scroll cuts to round the corners, a full permitier 1/4” roundover around the top, and a rough and finish sand.
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The doublers are jsut chopped for length, sanded, and then glued and screwed into the bottom, to provide a stable foundation for the legs, and to reinforce the top. This is one STRONG bench.
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It takes me about two hours to build one, start to finish (well, actually that's un-finished, but fully constructed); but if I were building a bunch of them it would probably only be an hour a piece because I could use the same setups over and over again.
Rather than use two full length doublers as I show in the plan views, I used the scraps of my previous cuts (oh and I freehand cut 2” radius corners, because I like them better than 1"). Either way, it’s plenty strong; though with the two full length doublers, glued and screwed, I’d guess the top would handle several thousand pounds without splitting.
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I believe Waddell rates their legs for 400lbs; I know that were it the right height I would have no qualms about sitting on this table, it's that solid.
Oh, and we chose the 24” x 36” dimensions for portability (JohnOC drives a Camry, and biggger table might not fit), and convenience using the plywood I had on hand; it would be trivial to extend the dimensions out to as much as 48"x32" and still only use a half sheet of plywood.
Honestly though, I like the smaller size. It’s tidy and convenient; and it makes a good lunch table as well.
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The cost? About $50 assuming you have the tools necessary to build it (Circular saw, power drill, skill saw, router, power sander); and about $300 if you don't.
The cheapest way to go is with some random rough grade plywood, but I'd really recommend against that. The generic 3/4” “hardwood” plywood that I used runs about $35 a sheet, and it works just fine. You might save $10 or $15 on wood, but your result won't be as good.
If you want better plywood, or thicker plywood, it’s more expensive. Going up to a full double layer of plywood would bring your wood costs way up; but that would make it 1.5” thick, and suitable for long term use as a workbench or something similar.
You could also do a double layer of 1/2” ply instead, for a solid inch of thickness; and it would be quite strong, lighter than the double 3/4", and probably handier; plus 1/2" thicnkess of good hardwood plywood is a LOT cheaper than 3/4".
Hell, if you have access to a marine supply place, they sell teak plywood that would look awesome and last about 1000 years; but would be a bit expensive.
If you are going to do any gunsmithing (or other work with hammering, clamping, and the use of solvents) on it I suggest surfacing it with 1/4” MDO board, or a hard surfaced laminate or particle board; which I would run you an extra $20 or so.
If you want a bigger one, you can do that, all the way up to as I said 48x24, or 48x32; which in addition to being a shooting bench, would make a decent portable picnic table for four to six people; a good folding desk or worktable etc… and the expense is just about the same. The wood costs the same, but it’s a bit more time, and a bit of extra sanding, gluing, and screwing.
You actually could go bigger, but I wouldnt recommend it; the table wouldn’t be as stable, and you'd use more plywood.
For finishing, I recommend marine spar varnish or something similar. I used six coats of heavy duty acrylic, but that's because I needed it dry in 24 hours; otherwise I'd have put 4 coats of spar varnish on.
For a seriously tough finish, seal it, and put three coats of marine varnish on it; but don’t expect a furniture grade finish. If you want that, you need to use more expensive plywood, like a good oak, beech, walnut, or birch furniture grade wood. Then you have to do a LOT of finish sanding; including sanding between coats; and put on three or four more, thinner coats; but honestly why bother.
I'll post some pictures of the fully finished benches tomorrow after the last coat of acrylic dries.