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Hello all, I have this really big workbench for my woodwork projects, however the top now needs to be replaced as it is quite damaged and is also warped in parts which makes the surface uneven. It currently has an MDF top but I am not keen to replace with new MDF. What would you suggest I get to replace the MDF? Ideally I want something that will not swell greatly if moisture comes in contact. I need something hard wearing that comes in large enough sheets to cover in one piece. The bench is about 7ft long.
Hi @caxelby
What a great work space you have for many projects Nice
I would like to talk to you about options so you may choose your new direction. I hear you as to the warped top and that is also telling me the wood under the you current table top is on is also most likely problematic too if you try remove the current top off the table carcass, What I am saying is it might be wiser to leave your warped top on and screwing a new panel on top as the weight should flatten most warping and will be flat and smooth by the time a heavier panel added. Any thicker panel will raise bench height by that amount you can always trim table legs to compensate.
Now I personally use my table ( a smaller version of yours close enough) I choose to put a 19 mm ply on top as a scacrificial table top . I can drill into it hammer items on it an not care if if hurt it as I do a range of heavy work and at the end of the day I unscrew that sheet and turn it over and it is mostly a like new again. Its being 10 years and i havent turned mine yet. My table has marks and scratches I love because it is usable.
Option A Ply in various sizes thicknesses and quality of finishes. seal it with polyurethane increase water resistance . if you make table top larger by an inch water will be less likly to wick into lower table top crack fill first and seal it with polyurethane too
Option B Structual flooring (Partical board red tounge) is designed to with stand Edge wax coat and wax impregnated to resist moisture Guaranteed 5 months exposure to the elements thats unsealed in its raw form. if you seal it with polyurethane both sides as a precaution it will be all but waterproof, https://www.bunnings.com.au/3600-x-800mm-22mm-flooring-particleboard-red-tongue-structural_p0148881
Bunnings will cut to size and ask them for aloan trailer or delivery option as you need.
You said your table seven feet table is approx 2130 mm (which is great as many standard material sizes are larger at 2400mm or approx 7.85 feet that simply means you can have Bunnings cut a new panel to size for you. The other key thing is the width of your table I am estimating your width is 23 inches to 27 inches approx 600mm to 700mm. So please measure widith too to help us find you a one piece ready made bench top.
You can always join butt up pieces together but never 100% nice.
Have you ever considered cutting timber to size and gluing them together to make a solid bench top hardwood or softwood? this would be one heavy duty work bench near indestructable. If you choose this option we can flesh out to idea more. but requries big clamps and you will need to plane the top flat which is a modest skill
I would not recommend any laminated nice looking panel as it will be scratched up in no time and prone to absorb water like your old bench top and fail.
The following may require two panels joined together and they are oiled and will require oiling again every 12 month so not ideal but a bunnings offering. https://www.bunnings.com.au/2200-x-600-x-26mm-acacia-solid-oiled-hardwood-project-panel_p8330032
If your work bench is light duty you can have the really nice stuff.
https://www.bunnings.com.au/interbuild-karri-2000-x-800-x-26-mm-timber-panel_p0403226
REALLY nice benchtop real wood photos dont do this justice I have seen in store.
This one is particularly nice with a natural timber shaped egde(live Edge ) and 30mm thick but is only 635mm wide ie 2 feet wide you will need two of these back to back cut to size to have live edges both sides an make it wide enough. I would over hang this panel on your existing table top and use the off cuts to put in vertical trim attached to your current desk vertical all round except for draw area.
https://www.bunnings.com.au/interbuild-2200-x-635-x-30-mm-senna-1-live-edge-timber-panel_p0403227
Well @caxelby I know other will help you too so thats great to help you find your solution enjoy your project ride
Hi @caxelby,
It's great to see you've already received a helpful reply from @Jewelleryrescue.
To throw another option in the ring, how about some Formply? It has a durable surface and is available in sheets large enough for your workbench top. It has a cross-lamination of the timber plys, so it's unlikely to be affected by moisture like the MDF.
Please let us know if you have any questions.
Mitchell
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