A few years ago, I inherited a Black & Decker Workmate from my father-in-law. I guess I would never just go out and buy one of these things, but the more I used it, the more I enjoyed its convenience, particularly for planing the edges of boards or router work. Before, I had been using C-clamps, which are inconvenient. I also use it to support my benchtop planer when I'm using it. I'll typically do such work outside, at the edge of the driveway, where I don't have to bother with cleaning up the shavings.
The plywood top of the thing was fairly shabby when I got it, and then it got left out in the rain. Strangely, B&D did not use marine grade plywood for the top:
I thought about what would be a cheap, effective way to make it weatherproof, as it's kind of in the way in my small garage. [I need a shed!] Settled on HDPE, which nearby Moses B. Glick's industrial surplus yard stocks in all thicknesses (1/8" to 2") and sizes. Got a 2'x 4' piece of 3/4" thick stock for $20, and went to work on it. Here's the end product:
While I was at it, I increased the surface area of the top by about 1/3. Also got some more holding pegs (the red ones) on eBay ($15). I used plastic model cement and countersunk 1-1/4" drywall screws to add the strips on the bottom side which doubles the top's thickness at the clamping edge, in the original configuration.
Back in business!
Thick sheets of HDPE can be a challenge to work with when machining, if there is a lot of heat generated. The heat melts the plastic, which then wants to seize the cutting tool. Router and power edge planer - not a problem. Spade drill bit, problem. Table saw, BIG problem. Just takes some care to clear the material removed at the cut as it tends to congeal and cause binding, I was able to cut 6-8 inches at a time, then stopping to clear the saw kerf and then repeating.
Next, I'm going to use this HDPE material to make a couple of new bird feeders. Weatherproof, and disinfectable. Drainage will need to be carefully planned, as rain will soak into a wood feeder and not puddle. Not so with plastic. Stay tuned!
-Paul
The plywood top of the thing was fairly shabby when I got it, and then it got left out in the rain. Strangely, B&D did not use marine grade plywood for the top:
I thought about what would be a cheap, effective way to make it weatherproof, as it's kind of in the way in my small garage. [I need a shed!] Settled on HDPE, which nearby Moses B. Glick's industrial surplus yard stocks in all thicknesses (1/8" to 2") and sizes. Got a 2'x 4' piece of 3/4" thick stock for $20, and went to work on it. Here's the end product:
While I was at it, I increased the surface area of the top by about 1/3. Also got some more holding pegs (the red ones) on eBay ($15). I used plastic model cement and countersunk 1-1/4" drywall screws to add the strips on the bottom side which doubles the top's thickness at the clamping edge, in the original configuration.
Back in business!
Thick sheets of HDPE can be a challenge to work with when machining, if there is a lot of heat generated. The heat melts the plastic, which then wants to seize the cutting tool. Router and power edge planer - not a problem. Spade drill bit, problem. Table saw, BIG problem. Just takes some care to clear the material removed at the cut as it tends to congeal and cause binding, I was able to cut 6-8 inches at a time, then stopping to clear the saw kerf and then repeating.
Next, I'm going to use this HDPE material to make a couple of new bird feeders. Weatherproof, and disinfectable. Drainage will need to be carefully planned, as rain will soak into a wood feeder and not puddle. Not so with plastic. Stay tuned!
-Paul
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