So how would you go about making it? What wood would you use?
Also material must be under 300.

I was leaning toward edge jointing some 11ft long 8/4 oak, maple or hickory depending on the price of the wood locally.

Thanks Glenn

Update: I just finished it, thanks for the advise.

Well due to all the advise given my frind used had a formica counter top commercially installed for the majority of the counter surface. However his client "the person having the house built" insisted on having a portion of the counter top made from solid maple.

I ended up using 8/4 hard maple laid on edge and then glued together. I started by riping strips 1.75" wide and gluing them together in sets of three. I then ran each set over the jointer and through the planer until they were just a hair over 1.5" thick and then I glued them all together. Even with cauls there was a little slippage but it the majority of it was "easily" cleaned up with the belt sander. A widbelt drum sander would be nice. I finished it with 6 coats of hand rubbed tung oil. Final dimensions were 38" by 25 1/2" by 1 1/2".

Personally, I'd lose the wood idea - cleaning game is messy work and it'll just beg for bacteria and other goodies. I'd suggest going with particle board or MDF and laminate it with Formica. That'd at least give you a surface that can be relatively cleaned.

Jason Beam
Sacramento, CA

In loving memory of Robert Bolton. We'll all miss you, Sir.

11 feet long by 24 inches wide by 2 inches thick - is about 88 board feet. Wood price varies WIDELY across the country but round here Maple is about 8.00 a board foot. Simply calculation means that's about $705.00

Soo - out with at least that kind of wood.

I would make a sort of torsion box construction box top. VERY VERY strong and stable. I would make a formica top and trim it out with Ash. This top is going to be just over 2-5/8 thick and VERY VERY heavy and SOLID. Throw a moose up there if you want.

If you want a pic of this bench let me know and I will post it.

FOR an 8' bench top: (if you want a 12' bench, modify as needed)
**This is just the top – not the cabinet**

4 Lowes FIR 2x4’s @ 2.50 ea =========================== $10.00
1 Sheet of ¾ sanded one side pine ply @ $40.00 ------===$40.00
1 Sheet of 3/8 sanded one side pine ply @ $40.00 -----==$40.00
box of 1-1/4 screws ----------------------------------===$6.00
box of 1-5/8 screws ----------------------------------===$6.00
Box 0f 4” screws -------------------------------------===$6.00
Glue -------------------------------------------------===$6.00
1x4x12 Ash @ $5.00 bd/ft -----------------------------==$20.00
1 4x8 sheet of formica -------------------------------==$50.00

Total cost is about $185 - $200

Should be able to make this in a full 2 day weekend

1) Get the best Lowes "FIR" 2x4's you can get. 4-5 of them
2) Cut 2 of them into 24" long pieces
3) Face joint them
4) Edge joint one edge - true to jointed face
5) Plane all pieces to thickness
6) Rip all pieces to uniform width
7) Miter the two long pieces so that they are exact same size - and to 94"
8) Miter two short pieces so they are exact same size - and to 23"
9) Lay the 4 pieces on a flat surface (like a picture frame) - shim of brace as needed.
10) "Clearance drill" and counter sink and holes in each corner for 4" long screws.
11) GLUE - GLUE and screw the 4 corners together. Make sure everything stays flat.
12) Check diagonals.
13) Cut a 3/8 thick sanded one side plywood to exact size of frame.
14) GLUE - GLUE and screw to bottom of frame with 1-1/4 sheet rock screws
14) Cut (FIT) short 2x4's to fit at desired intervals (24" or so)(fit around sink opening area)
15) GLUE- GLUE and screw through the 3/8 plywood --- AND --- with 4" screw through fornt and back edges.
16) Cut a 3/4 sanded one side plywood top.
17) GLUE - GLUE and screw top to frame with 1-5/8 sheet rock screws
18) Trim edges on table saw - or circular saw IF needed.
19) Trim with Ash and be sure to be flush - top and bottom.
20) Random Orpital sand the top to make edges flush and ply smooth
21) Apply laminate top
22) Chamfer all around top front and side edges.
23) I like to corner round bottom edge.
24) When attaching to base – make base so that there is 2” minimum overhang all around. This will allow for real nice clamping surface.

Caution:

If you decide to make this top – be forwarned – it is very very heavy and awkward to move around. Ask for help when moving it.

Leo

Before the 04 crash;
Member since October, 2003

Do it right!

I plan on trying this in my garage or laundry room at some point, but haven't got to it yet.

Mark F

My opinion,

John