Hello this instructable will go through basic steps to make a solid, large work bench or work desk for your home or business area.
- Made at Techshop (www.techshop.com)
Step 1: Buy materials
Materials used for this work desk:
4 leg pieces - I used 2"x2" square profile steel tubing, 1/8" thick, 28" long (after final cut)
4 square table mounting pieces - 6"x6" x 1/4" thick steel, wit 4 holes drilled near corners to attach final welded legs to wood table underside
4 metal bases - One large 12" x 40" x 1/4" thick steel piece which was plasma cut to make 4 bases for the 4 legs
Metal cost: ~$60-80 depending on where you go to get the metal and if you can use some scrap/salvage metal
1 solid core wood door - cut down to specific size, 32" x 60" birch, 1 3/8" thick
Wood cost: ~$80
Wood stain + polyurethane varnish (or spray cans) - I used matte for wood, gloss for metal legs to increase shine
Wood mounting screws
Felt sticky pads to put under table legs and prevent floor scratches (+ allow easy movement)
Supply cost: ~$40
Total work desk cost: ~$200
Comparable furniture design store cost: $1500-$3000
Step 2: Cut metal bases to length
Use horizontal band saw to cut metal leg pieces to correct length. Typical sitting table height is about 29" so I cut the legs to 28". This allows 1 3/8" for the top wood, 1/4" + 1/4" for the metal leg top and bottom pieces and ~1/8" for the carpet/sliding fabric to be put under the metal legs to prevent floor scratches.
Step 3: Polish legs
Use hand-grinder and course lap wheel to polish metal legs. They can be put next to each other and moving back and forth you can create a scintillating pattern along the length of the leg for effect.
Step 4: Plasma cut metal bases
Using Corel Draw, you can create any pattern for the plasma cutter to carve out desk feet. I chose a rounded triangle pattern shown cut out of the 1/4" metal piece. Plan to make more bases than you need to have 1-2 spare if needed.