I'm going to make the portable Paulk Workbench

http://s50.photobucket.com/user/pmaru77/slideshow/Work%20Bench

Surprizes: I bought a hole saw from Harbor Freight (HF) and got 3 saws for $12 and the biggest one was 4.25". It made it through all the 52 holes (barely, be patient) but I did ruin my cheak B&D drill press motor. I'd suggest going with 1/2 material for those parts to save the aggravation of putting the large holes in thicker material. I picked 3/4 for that unfortunately. I thought it would be better for the pocket screw holes.....but if 1/2 works.....do it. You will be glad when it comes to the large holes. Plans call for a 4.5" dia hole but HF only had 4.25. I doubt that the 1/4 will kill me. But may make it harder to get tools in and out of.

The advice to make one cutout and then use as template is not what I did. The length of the 4.5 slots is not critical, but the location of them from the top or bottom may make the next cuts easier to line up. I pre drilled the center for the large holes with the same size as the pilot on the 4" cutter. If you drill them on a drill press, you can make them all the same diatance from the edge, so when you make the next cuts, it will be easier to line up your circ saw. I used a compound mitre saw for the short pieces and the festool for the long pieces. It only takes 10 minutes to lay out the location lines for the drilling for the large holes.

I used a dremel to blend the 4" holes whitht hehoriz cuts, and did not use a jigsaw which is the choice in the plans. that may do a better job of blending and not have to use the dremel, but my waste pieces basically just fell out after sawing with the circ.

Pocket holes are next because I have the tools. Still wondering how I'm going to put in the many many many 3/4 holes in the deck. Plans call for router bit, but I do not have the bit or a plunge router. So I'm stuck on that one. I'm counting 200 pocket holes! That is just for the 2 tables.

update with photos



Resting up for next steps. No glitches or surprizes. Forster bit worked fine for the zillion 3/4 holes. I used scrap for backup when drilling, and if you put a lot of pressure on the wood just before it breaks through, you will get a cleaner hole on the other side. I pressed down hard on the wood with my left hand while drilling with the right......just pressing the drill down and not the wood results in a lot of splinters on the back side....though not all that improtant. I glued the decks to the frame, but no glue on the frame to frame parts. Why? Lazy. I plan on using some leftover West Marine epoxy on the inside joints befor I close up the bottom. I will also epoxy some other parts to prevent splinters.

More updated pics on the Photobucket file above also.

A lot of work to make this thing. I hope to be able to take advantage of as many functions as I can get out of it. The router table adaption is my next challenge.

I finally got semi started today. I'm drilling the holes partially with a spade bit for alignment. Then using those partial holes, I'm boring the thru hole with a $14.00 MLCS HSS 3/4" bit. Seems to be working. I have the 2 tops clamped over one of the upside bottoms, so punch through won't be seen and a little dimpling will give the bottom some art appeal....
Boss lady just put me on another task....Later!

I finished mine last week and kind of forgot about your thread. I also mounted a vise and router station on the other side. I pocket holed everything. For the bottom, I drove the screws with a right angle drive.
I used my tracksaw to connect the holes. Ron said he did also.
Here's some pics.

I boxed the area under the router plate for extra support and dust collection.




Added this vise. And the Grizzly clamps work great.



Hadn't planned on the pipes, I'm going to just for the handles :laughing: