Need help with building a workbench top with glued 4x4s

I would use plywood instead -

The four-by-fours are overkill for anything you will do on a bench that size. And they will yield an inferior end result.

Because you want a solid, accurately flat worktop and the four-bys will work against you in that regard. They will be silly-heavy and contribute nothing useful.

My suggestion would be to frame the top in two-by-fours on edge. Use six equal spaced two-by-fours the short way.

Make the legs out of an angle formed by a two-by-three and a two-by-four - screwed and edge-glued. These will also block and gusset the inside corners of the two-by-four top-frame. Frame a shelf inside them about 8" or so up from the floor. A single layer of 3/4 plywood glued and screwed down on top will be plenty but you could add a second layer of it too. Double 1/2" ply might cost less.

If you make it flush-edged with the top framing you can add a one-by detail and slightly chamfer the top outside edge against chipping. Oak would be nice but pine will be fine.

Of course it's just my opinion; I could be wrong. <g>

PHM
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blue sky said:

I'm building a bench top made with Douglas Fir S4S 4x4s and want to make sure my plans/techniques checks out before I start. The dimensions are 28" x 58". I'm planning to simply glue them together with Gorilla Glue, then clamp together overnight to dry. Is this all there is to it to make a strong bond and quality top or should I be thinking about doing it another way?

Thanks.

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