The work table in the picture above was created from items that were left out as free to someone who would haul them away. The tools and materials required for this project are: chop saw, welder, grinder, skill saw, biscuit joiner, belt sander, palm sander, bar clamps, 400 ml of wood stain, 900 ml of Polyurethane Clear Satin, 800 ml of Carpenter's glue, 40 #20 2 3/8" x1" biscuits, paint sprayer, 2 paint brushes, 5 used 8' x 30" x 2" solid wood doors, 5 - 8' x 2 1/4" used pieces door moulding and 6 - 10' x 2" x 6" pieces of used steel shelf racking.

Step 1: Finding the Material for Your Project.

I was lucky when I wanted to build a 5' x 10' table that would be strong enough to work on. I just happen to have a trailer load of old doors and the moulding that my father-in-law brought me thinking I would have some project I could to use them for in the future. Well, that day came for some of them. The racking was about too go on sale for anyone that would pick it up and haul it away for free.

Step 2: Building the Frame 8' X 4' X 30"

Building the frame was very straight forward, find pieces in the junk pile longer than what was needed cut the ends off and weld together.

Step 3: Building the Table Top

Using a skill saw, I cut 1" off the sides of the doors, then cut 3 pieces 20" x 60"

and 2 pieces 30" x 60". I marked up the pieces as to where I would but the biscuits, every 6".

I cut all of the biscuits then glued up the doors in 2 stages; first the 3 - 20" x 60" pieces letting them sit over night, the next day adding the two end pieces. Clamping the end pieces on was a bit of a challenge since the table was 10', I needed to use 3 clamps to make the proper length.

Step 4: Prepping the Top and Adding Trim

I cut the 2" door trim to proper lengths with metered corners, then ruled and nailed it to the frame. After the glue was dry I used the belt sander on the top and sides, first with 80 grit to take off the old finish, then with 120 grit to smooth things out. Next I went to my palm sander with 120 grit then 220 grit to make a nice smooth finish.

Step 5: Finishing Top

I wanted a nice dark finish as I find it hides the little imperfections well, so from the photos above you can see the first coat of stain then the second coat. I then finished the surface with one thick coat of clear satin finish polyurethan.