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Today we glued up two chunks of what will become Managing Editor Megan Fitzpatrick’s workbench.
For those of you just tuning in, I haven’t broken my vow of workbench chastity. The bench design isn’t new (it’s actually quite old), but the material we’re using is. The whole thing is going to be made out of LVL , laminated veneer lumber. So this is a story about a new material. Really. And it’s Megan’s bench, not mine.
After slicing into the LVL on the table saw I learned some of the finer points of this engineered material. Because of the laminations, there really aren’t any stresses in the planks. It cuts easily, like nice plywood.
I ripped each LVL 2 x 12 into four 2-3/4″-wide strips. Then I jointed the solid-wood faces of each strip. The nice thing about LVL is that the faces are thick enough to withstand a couple passes on the jointer before you cut through the lams , it’s like thick, old-school veneer.
The bad thing about LVL is the seams. Every six feet or so there is a scarf joint where the lams overlap one another. These seams determine the direction you should run the material over the jointer. I jointed one of them in the wrong direction and was rewarded with a big splintery bite at the seam. I’ll never do that again.
The material is fairly consistent. The first plank I sliced up was dimensionally perfect in thickness and width. The second one was not. One end was a little thicker than the other (about 1/16″) and the plank had a pronounced crook , but only on one edge. Crazy.
The only other bad thing I have to say about LVL is that because it’s (usually) made from Southern yellow pine, it’s pretty dang splintery. I’m in Detroit tonight for a photo shoot tomorrow and let’s just say I brought some LVL with me for the ride.
We glued up the two slabs with regular Titebond and left them in the clamps overnight. Yellow pine can have a lot of resin, which resists waterborne glues. So Titebond’s resident pointy head (Dale Zimmerman) recommends we leave it clamped for at least five hours. We’ll glue up the remainder of the top on Friday.
How will we flatten it? I’m still working on that. Megan keeps bringing up the fact that Senior Editor Glen D. Huey has a wide-belt sander that can handle a 24″ top.
– Christopher Schwarz
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I’m waiting to see this one finished too. Always interested in finding inexpensive materials for a good "first" workbench.
Indeed. I’ve got to finish two other projects before we get back on this one.
Should be soon….
Chris
Interesting project, any progress – been kind of quiet for a while now?
Anders
Very interested in how it works out. I bought several LVL more than a year ago with the exact same plan. Also contemplated just using them on the flat and biscuiting or bolting them together. This material is very stiff compared to standard 2x softwood construction material. I have stood in the middle of a 16 foot piece (on the flat, held only at the ends – 180+ lbs) and there was very little deflection compared to a similarly sized piece of fir. It is very hard and very heavy.
If LVL can remain stable in Cincinnati’s humidity variations it could be a major bench wood.
It’s fairly stiff. But I’m not sure how the seasons will treat it. That’s why we’re experimenting with it.
Chris
I assume that LVL will not warp or be subject to seasonal distortion – flatten it once and be done. Does LVL have any flex?
The entire bench will be LVL. That’s the plan at this point.
Chris
We have one local lumberyard, McCausey Lumber, here in the Detroit area that sells those laminated beams. It is an interesting piece of wood. I can’t wait to see the finished work bench top.
What will the legs be made from?
That is going to be one wild looking workbench, and I bet with the lamination’s, it’ll be strong as a horse!
On adhesive: An epoxy would work, as would a poly glue. Both are more expensive than yellow glue, which we have a gallon of.
And we’ll use a gallon of it I’m sure.
Chris
Jared,
We’ll likely paint the base. The top will get an oil/varnish blend. Once you’ve seen this stuff finished, I think you’ll be impressed. The front edge of the benchtop is a tough question. Personally I’m happy with working with the face grain from one of the plies. But if this has to go in a magazine, I might opt for a little veneer work.
We’ll see!
Chris
Would a slow-dry epoxy be appropriate for this kind of glue up?
You say its Megan’s bench but you’re building it. Admit it, you’re hooked, you’re a workbench junkie.
David,
It’s actually going to be just shy of 8′ – I like to build big stuff. The best thing I have to say about LVL (so far) is that Chris is really enjoying getting to know the material. Notice how he did all the ripping and jointing…good thing, too – I took the slabs out of the clamps just moments ago, and I can barely lift them.
Megan
Yes, ‘splintery’ is the first thing that came to mind when I read that you were making a benchtop from LVL… hopefully it works out.
Looking at the glue-up picture, I’m guessing this bench is going to be a 12 footer. That’s huge – I’m surprised that there’s that much room in your shop!
Yesterday a tornado warning came on over the radio’s emergency broadcast system. The suggestion was to get to a basement and get under a workbench or other sturdy piece of furniture. If I’m ever visiting the area and a tornado warning is issued, I call dibs on this bench!
Chris,
Next time you get to the Detroit area, give a shout and we can explore the local scene.
Hope you enjoy your time here in the D!
Britt,
Just glue. While biscuits or dowels are well-intentioned, many alignment schemes go awry. I have very good results with just shifting things and clamping.
The bench will indeed be a brute. We should be able to park a truck on it.
Chris
Did you biscuit or dowel those at all or just glue?
I’m loving this material so far, can’t wait to see the final product. Too many workbenches look pristine and untouchable, I think this one will avoid that though.