When we upgraded our electronics bench setup, we wanted a new table that was cheap and incredibly easy to assemble (and disassemble / transport for moving).
Our solution? Turn two 4'x8' sheets of 23/32" plywood into a slot-assembly, no-screws-needed project bench, that can be assembled and disassembled in under two minutes. Let's get started!
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Cutting Time: ~3 hours
Assembly Time: 2 minutes
Cost: $65 for plywood, $70 for optional enhancements
We've provided the solidworks parts/assembly, the vector DXF files, and the VCarve Pro project files, so feel free to take them open and have a look at how everything fits together. We didn't include the toolpaths, as those will likely change depending on the dimensions of the board you're cutting and the specs for your mill.
When you're ready, open up your toolpath creator of choice (we used VCarve Pro) and lay out your parts. If you haven't done toolpath creation before, we recommend taking the TechShop CAD/CAM course or looking at some online tutorials to help speed the learning process.
If you're not using the provided VCarve Pro project files and want to work directly from the DXF files, be sure to join the imported vectors and apply dogbone fillets to the corners so that your parts will fit together without sanding. We've attached pictures on the next step showing the dogboned vectors, so match against this to make sure you get every corner.
Our bit was configured as a 1/4" 2-flute HSS end mill, at 12000 RPM, 288 IPM feed rate and with a 30 IPM plunge rate. We used profile toolpaths exclusively, 6 passes with climb milling. Make sure you're milling Outside/Right for the outer perimeter and Inside/Left for all cuts inside the part, or things may not fit together!