DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE

ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.

INDEX:
PAGE 1. COVER PAGE
PAGE 2. GENERAL NOTES
PAGE 3. MATERIAL LIST/CUT DIAGRAM
PAGE 4. CUT LIST
PAGE 5. PLAN VIEWS
PAGE 6. EXPLODED VIEWS 1
PAGE 7. EXPLODED VIEWS 2
PAGE 8. EXPLODED PLAN VIEWS
PAGE 9. EXPLODED DETAILS
PAGE [Link] DETAILS
PAGE 11. ROUTER FENCE & MATERIAL/TOOL PRICES PLUS LINKS

PAULK DESIGNS
1004 Commercial Ave #1091 ANACORTES WA 98221
[Link]
crpaulk@[Link] 360-391-2090
PAULK WORK BENCH II
WITH ROUTER TABLE
 DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.
Notes:
1. All metric dimensions are derived by converting standard imperial 13. Cut pipe guides and pipe stops. Drill holes for pipes in the six 38. Screw bottom to assembly with 1 ¼" bugle head wood screws. They
dimensions. Take care to confirm and adjust metric dimensions to guides. Confirm O.D. of pipe for holes size. Mark center point of pipe should be counter sunk to prevent scraping on other surfaces during
standards available in your region. guide on bottom edge of guides. transport.
2. Plywood has a smooth and rough side. Be sure to mill parts to have 14. Drill pocket holes on top edge of sides as shown. 39. Repeat #36 & #37 on second assembly.
the smooth side out. Pocket holes should be drilled on rough side 15. Drill pocket holes on top edge and both ends of all spreader/end- 40. Route out slots on both bottom assemblies to receive saw horse tabs
which will also hide pocket holes inside of bench. caps as shown. per plan.
[Link] saw set up is for the Dewalt 744. You will need to make ASSEMBLY. 41. Route out router access hole as shown on plan.
modifications for other brands. 16. Place one top with holes drilled face down on your 42. Set up saw horses and place both tops on horses and tighten bolts
assembly table or work surface. securing tops together.
Recommended order of construction: 17. Screw together two sides and five spreader/end-caps with pocket 43. Cut and assemble table saw mounts.
screws. (USE WOOD GLUE AT ALL JOINTS) 44. Attach table saw mounts to table saw with 2 screws on each mount.
1. Rip all material for tops, bottoms, sides, spreaders/end-caps, 18. Pocket screw assembled structure to top. (USE WOOD GLUE) 45. Place table saw on pipes and measure the amount table saw is above
and saw horses. 19. Wipe up excess glue with damp cloth. surface.
2. Cross cut spreaders/end-caps and saw horses. Note: 20. Repeat steps 16-19 on 2nd top assembly. 46. Remove table saw and remove mounts.
plywood thickness will dictate spreader/end-cap length. 21. Clamp both assemblies together with tops down. (Bottoms are 47. Cut off the amount measured in #45.
Measure final top/bottom width and deduct double the not yet attached allowing access to inside of table.) 48. Mount table saw mounts with screws and place table-saw on pipes.
plywood thickness for exact length spreader/end-cap lenght. 22. Drill ⅜" (10mm) hole though sides on each end as shown. 49. Confirm table saw is flush with surface. Recut if necessary.
3. Make one saw horse side w/tabs using hole saw, circular 23. Remove clamps and separate the two assemblies. 50. Layout and route dados for table saw miter gauge per plan.
saw, jig saw, and sand cuts. 24. Drill 2" (50mm) holes as shown above ⅜"(10mm) hole intersecting 51. Layout and route miter slot for router table per plan.
4. Use completed saw horse side with tabs as template to ⅜" (10mm) holes on both ends of one side only. Remember your 52. Layout and route hole for router plate.
route 3 more saw horse sides with tabs. Use router with assembly is upside down so 2" (50mm) hole will be below ⅜" (10mm) 53. Route slots for router fence.
spiral upcut bit and template guide. hole when tops are turned over. This creates a key hole on each end. 54. Drill holes for router fence removal in each end of router slots per
5. Cut the tabs off two of the saw horse sides using circular 25. Place ⅜"(10mm) bolt, two fender washers, and Plastic T-nut plan.
saw. assembly though ⅜" (10mm) hole on each end. (The bolt assembly is 55. Unbolt and separate tops and drill holes in sides at router fence slot
6. Sand all surfaces and round over all edges of saw horses with permanent and never again needs to be removed.) for uninterrupted movement of router fence.
⅛"(4mm) round over router bit. 26. Glue and pin backing to underside of tops for table saw crosscut 56. Sand all surfaces and round over all edges of table top assemblies
7. Assemble saw horses using nylon straps as top hinges and dados, router table miter slot, and router plate per plan. with ⅛"(4mm) round over router bit.
spread limiters. Use ½"(12mm) washer-head wood screws as shown 27. Bolt together the two complete assemblies. Remember at this point [Link] table assemblies together and bolt.
and melt all ends of cut nylon to prevent unraveling. the assemblies are upside down and the bottoms are not attached.
8. Using hole saw, circular saw, and jig saw to cut oval in one 28. Layout center point for pipe guides/stops. Screw pipe guides/stops Option 1: Build router fence per plan. This fence is a basic design and
spreader. Sand and clean up spreader, then use as a template to to spreaders/end-caps on layout and remember bottom of guides up as not my creation. I have provided it to help those that don't have a fence
fabricate (9) more spreaders and end caps. Use the same technique as you are assembling upside down. Do not use glue so that if your table or preferred design.
(#4.) saw changes in the future you can replace guides if necessary. Option 2: Make bottom shelf from ¾"(20mm) plywood. The shelf is not
9. Use spreader template to make one side paying attention to 29. Rough cut pipes to 6'. on plan or in material list.
layout as shown in plans and the same technique as (#4.) 30. Drill hole in end of pipes as shown on plans for ¼"(6mm) bolt to Option 3. Apply finish of choice to work bench. (I don't put a finish on
10. Use completed side as template for 3 more sides. prevent pipes from pulling out once installed. my work bench.
11. Round over all edges of ovals in sides, end-caps, and 31. Slide pipes into guides and install bolts and nuts.
spreaders with ⅛" (4mm)round over router bit. 32. Push pipes in until they hit pipe stop. It is all done, now put it to work!
12. Stack both tops and clamp, pin, or screw together. 33. Mark pipes where they are flush with pipe guide at end cap.
Layout bench dog holes as shown in plan. Using ¾"(20mm) 34. Using pipe cutter, cut pipe at mark.
spiral up cut router bit, bore holes on layout through both tops. Use a 35. File cut end of pipes to round over and remove burrs.
straight edge as guide to assure holes are aligned. 36. Apply glue to edge of sides and spreader/end-caps and place bottom
on the assembly.
37. Drill and counter sink holes through bottom into sides and spreader/
end caps.

APRIL 7, 2013 GENERAL NOTES PAULK WORK BENCH II 2

 DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.

21
20
18
19 19
8 8 22 22 22 22

12
MATERIAL LIST IMPERIAL/
METRIC
11 10 OPTIONAL ROUTER FENCE
1 2 3 4 5 6 7 5
11 10 11. (1) 16"(940mm)x30"(760mm)
8 8 12 Sheet ¾"(20mm) A/C Ply
17
12. (6) Plastic Knobs w/1/4"(6mm)
9 threaded open end.
23 9 13. (6) ¼"(6mm)x2 ½"(64mm) hex
13 bolts.
14. (8) ¼"(6mm)washers.
15. (16) 2"(50mm)wood screws.
8 8
8

18 17

14
8

8 8

1515 15 15 15 15 16 16
1" ELECTRICAL CONDUIT

PART NAMES ½" (12mm) A/C Ply: IMPERIAL MATERIAL LIST METRIC MATERIAL LIST
# QTY. # QTY. WOOD: WOOD:
1 . (5 )4 8 "x 9 6 " Sh eet ½" A/C Ply . 1 . (5 )1 2 1 9 m m x 2 4 3 8 m m Sh eet 2 0 m m A/C
1. 1 Bottom 13. 1 Backing for router miter slot HARDWARE: Ply .
SCREWS NYLON STRAP BOLTS,NUTS,
WASHERS 2. 1 Bottom router side 14. 1 Backing for router miter slot 2 . 8 ' 1 ½" Ny lo n Stap HARDWARE:
3. 1 Top 15. 6 Pipe guide 4 .(2 )Plastic No b s with 3 /8 " th read ed 2 . 2 4 0 0 m m x 4 0 m m Ny lo n Stap
4. 1 Top router side 16. 2 Pipe stop o p en en d to allo w b o lt to p ass th ro u g h . 4 .(2 )Plastic No b s with 1 0 m m th read ed o p en
(Win g Nu t will wo rk ) en d to allo w b o lt to p ass th ro u g h . (Win g
5. 2 Side-Out side 17. 2 Saw horse w/tabs 5 . (4 ) 3 /8 " Fen d er Wash ers Nu t will wo rk )
6. 1 Side-Inside non-keyhole 18. 2 Saw horse 6 . (2 ) 3 /8 "x 2 ½" Hex Bo lts 5 . (4 )1 0 m m Fen d er Wash ers
7. 1 Side-Inside keyhole Optional Router Fence ¾"(20mm) A/C Ply 7 .(2 ) 1 " i.d . x 6 ' electrical co n d u it. 6 . (2 )1 0 m m x 6 4 m m Hex Bo lts
8. 10 Spreader/End-cap 19. 2 Adjustable fence 8 . (2 ) ¼" x 1 ½" b o lt. (Fo r p ip e en d s) 7 . (2 )2 5 m m i.d . x 1 8 0 0 m m electrical
9 . (2 ) ¼" n u ts. (Fo r p ip e en d s) co n d u it.
9. 2 Table saw mount center 20. 1 Sub-fence 1 0 . (8 0 ) ½"wash er h ead wo o d screws 8 . (2 )6 m m x 4 0 m m b o lt. (Fo r p ip e en d s)
10 2 Table saw mount left 21. 1 Brace (Fo r attach in g n y lo n to saw h o rses) 9 . (2 )6 m m n u ts. (Fo r p ip e en d s)
11. 2 Table saw mount right 22. 2 Angle brace 1 0 .(8 0 ) 1 2 m m wash er-h ead wo o d screws
12. 2 Backing for table saw miter slot 23. 1 Vac Port (½" 12mm A/C ply) (Fo r attach in g n y lo n to saw h o rses)

APRIL 7, 2013 MATERIALS LIST PAULK WORK BENCH II A 3

 DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.
Drill 1"(25mm)holes with center at top edge.
1'11 7/8" 1 1/8" 6" 3 3/4" 3" 4"
606mm 455mm 152mm 95mm 76mm 102mm Drill hole = to o.d. of the pipe +

159mm
152mm

6 1/4"
12 1/16th (2mm).

200mm

190mm

178mm
203mm
9

7 1/2"
3/4" (20mm)

95mm
15

6"
1" Hole

7"
305mm

3 3/4"
8"

8"

8"
305mm

1' 2 1/2"
1' 0"

368mm
1' 5 1/2"
1'

445mm
127mm
4" 10 1/2" 4"
102mm

5"
1' 1 1/2"
64mm

343mm
6 7/8" 11" 6" 102mm

178mm
1" Hole 25mm
6 7

127mm
175mm 279mm 152mm 5 16

7"
5 9/16" 9 5/16"

5"
1' 5 1/2" 9"

11 13/16"
500mm

508mm
300mm
305mm
445mm 141mm 237mm 229mm

1' 8"

1' 8"

1' 8"
1' 0"
3"

45 angle
½"(12mm) Rabbet 76mm
7/16"(11mm) deep

216mm
8 1/2"
10 13

10mm
10mm
5 7/8" 10" 8"

3/8"

3/8"

1219mm
152mm 279mm 305mm 279mm 152mm

20mm
150mm 254mm 204mm

4' 0"

1' 11 1/4"
590mm
6" 11" 1' 0" 11" 6"

3/4"
1"(25mm) Hole 2 1/2"

102mm
1' 1 1/2"
343mm
64mm
17

4"
2' 6 3/4"
781mm

305mm
1' 0"
2' 5 3/4"
756mm

737mm
BOTTOM BOTTOM TOP Use 5"(127mm)
TOP

2' 5"
343mm
2440mm

hole saw for radius.

1' 1/2"
INSIDE INSIDE OUTSIDE 3"

8' 0"
8' 0"

OUTSIDE
LEFT RIGHT LEFT RIGHT
3/4"
11 76mm
1 2 3 4 (20mm)
4" 102mm

14

229mm

°
102mm

102mm
85
9"
965mm
3' 2"

1' 1 1/2"

1' 11 1/2"
343mm

597mm
1168mm 4"
4"
3' 10"

178mm
18

216mm
7"

8 1/2"

103mm
4 1/16"
102mm
4"
25mm 25mm
1"

1' 1 1/2"
1"
8

343mm

1' 10 7/8"
175mm 280mm 175mm 280mm
102mm

152mm 152mm

1' 1 1/2"

581mm
343mm
4"

6 7/8" 11" 6" 6" 11" 6 7/8"

98mm
3 7/8"
9 1/2"
242mm

242mm
9 1/2"

175mm

159mm
6 1/4"

103mm
4 1/16"
6"

1' 5 7/8" 6" 6" 1' 5 7/8" 7"

455mm 175mm 175mm 455mm 178mm
PART NAMES ½" (12mm) A/C Ply: 2"(50mm) hole 2"(50mm) from
# QTY. # QTY. end 3"(76mm) down from top.
Repeat on both ends. 45 angle
1. 1 Bottom 13. 1 Backing for router miter slot ⅜"(10mm) Holes 2"(50mm) from Counter sink bolt heads. both ends.
end 2"(50mm) down from top. 381mm 140mm
2. 1 Bottom router side 14. 1 Backing for router miter slot 1' 3" 19 5 1/2"
Repeat on both ends.

64mm
2 1/2"

114mm
127mm

4 1/2"
3. 1 Top 15. 6 Pipe guide 102mm
23

5"
4"
4. 1 Top router side 16. 2 Pipe stop
Center hole
5. 2 Side-Out side 17. 2 Saw horse side w/tab 45 angle the size of vac
6. 1 Side-Inside non-keyhole 18. 2 Saw horse side 2' 6" 20 hose.

2 1/2"
64mm

127mm
762mm
7. 1 Side-Inside keyhole Optional Router Fence ¾"(20mm) A/C Ply

5"
22

2"
11"
8. 10 Spreader/End-cap 19. 2 Adjustable fence 50mm

2 7/8"
1" 279mm

73mm
4"
9. 2 Table saw mount center 20. 1 Sub-fence 102mm

10 2 Table saw mount left 21. 1 Brace 381mm 2 7/8"

1' 3"
102mm
21 73mm
11. 2 Table saw mount right 22. 2 Angle brace

73mm
2 7/8"
4" 50mm

2"
12. 2 Backing for table saw miter slot 23. 1 Vac Port (½" 12mm A/C ply) 1' 8" (508mm)
2' 6" (762mm)

APRIL 7, 2013 CUT LIST PAULK WORK BENCH II 4

DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.

BOTTOM TOP

LEFT RIGHT

BACK

LEFT

RIGHT

FRONT

BACK
FRONT

APRIL 7, 2013 PLAN VIEWS PAULK WORK BENCH II 5

DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.

APRIL 7, 2013 EXPLODED VIEWS 1 PAULK WORK BENCH II 6

DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.

BIG EXPLODED VIEW TO STUDY.

APRIL 7, 2013 EXPLODED VIEWS 2 PAULK WORK BENCH II 7

DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.

FRONT TOP BACK

LEFT RIGHT

APRIL 7, 2013 EXPLODED PLAN VIEWS PAULK WORK BENCH II 8

 DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.

POCKET HOLES IN TOP ONLY OF SIDES.

TABLE SAW MOUNT SIZES SHOWN ARE NOT
THE FINAL DIMENSIONS.
INSTALL BOLT AFTER PIPE
INSERTED IN PIPE GUIDES.

95mm
3 3/4"
95mm

89mm

89mm
ROUTER PLATE DADO 1/16"(2mm) LONGER,
3 3/4"

3 1/2"

3 1/2"
1/16"(2mm) WIDER, 1/16"(2mm) DEEPER
THAN ACTUAL PLATE.

POCKET HOLES IN TOP AND

BOTH ENDS OF SPREADER/END-CAPS.
LEAVE FLAT EDGE ON BOTTOM OF MOUNTS.

ALL POCKET HOLES ARE PLACED ON INSIDE SURFACE.

TABLE SAW MOUNT PIPE BOLT PREVENTS PULL OUT POCKET HOLES ROUTER PLATE DADO

CONNECTOR BOLT ASSEMBLY INSIDE CONNECTOR BOLT ASSEMBLY OUTSIDE CONNECTOR BOLT KEYHOLE CONNECTOR BOLT KEYHOLE
KEY HOLE: FIRST DRILL ⅜" (10mm) HOLE THROUGH
BOTH ABUTTING SIDES ON BOTH ENDS. SEPARATE
ASSEMBLIES AND DRILL 2"(50mm) HOLE BELOW AND
CONECTOR BOLT ASSEMBLIES INTERSECTING ⅜"(10mm) HOLE.
REMAIN PERMANENTLY ATTACHED
TO ONE SIDE.

APRIL 7, 2013 DETAILS EXPLODED PAULK WORK BENCH II 9

DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.

AFTER BOTTOMS ARE GLUED AND SCREWED ON, DOUBLE

ATTACH PIPE GUIDES AND STOPS WITH SCREWS CHECK LAYOUT OF TABS ON SAW HORSES AND ROUTE
ONLY (NO GLUE) TO ALLOW ADJUSTMENT IN THE ¾"(20mm) SLOTS FOR SAW HORSE TABS.
FUTURE.

BEFORE ASSEMBLY STACK THE TOPS,

PIN OR SCREW TOGETHER, LAYOUT
BENCH DOG HOLES, USE ROUTER WITH
¾"(20MM) SPIRAL UPCUT BIT. ALSO, USE
A STRAIGHT EDGE TO ASSURE HOLES ARE
LINED UP. BY STACKING TOPS AND BORING
HOLES THROUGH BOTH TOPS AT THE SAME
TIME ASSURES IDENTICAL TOPS AND CUT
BORING TIME IN ½. ROUTE ALL OTHER
DETAILS: ROUTER PLATE, MITER SLOTS,
ETC.. AFTER ASSEMBLY.

TOP DETAILING NOTES PIPE GUIDES SAW HORSE SLOTS ANOTHER EXPLODED VIEW

ROUTER FENCE SLOTS NOTCHES (HOLES) FOR ROUTER FENCE ADJUSTMENT. ROUTER CLEARANCE CUT OUT MITER SLOT BACKING

½"(12mm) BACKING SHOULD BE GLUED AND PINNED

TO UNDER SIDE OF TOPS FOR ROUTER MITER SLOT AND
TABLE SAW MITER SLOTS.

CUT OUT ON BOTTOM FOR ROUTER CLEARANCE.

HOLES (NOTCHES) ON INTERIOR SIDES LINE UP

WITH ROUTER FENCE SLOTS TO ALLOW THE FENCE
TO BE ADJUSTED ACROSS BOTH TOP ASSEMBLIES.

⅜"(10mm) SLOTS W/1"(25mm) HOLES DRILL

ON EACH END TO ALLOW REMOVAL OF ROUTER
FENCE ON BOTH ENDS.

APRIL 7, 2013 DETAILS 2 PAULK WORK BENCH II 10

 DESIGN AND PLANS ARE THE SOLE PROPERTY OF RON PAULK AND ARE PROVIDE FOR PERSONAL USE ONLY. NO RIGHTS ARE GIVEN TO COPY, SHARE, EMAIL OR POST ONLINE IN ANY FORM.

ALL ¾"(20mm) PLYWOOD

DRILL ½"(12mm) ¼"(6mm) DEEP DRILL HOLES TO LINE UP

TO COUNTER SINK HEX BOLT HEAD. WITH ⅜"(10mm) ROUTER
DRILL ¼"(6mm) THROUGH CENTER FENCE SLOTS ON BENCH
OF COUNTER SINK HOLE TO ALLOW TOP.
BOLT TO PASS THROUGH.

THIS IS A QUICK, EASY AND CHEAP ROUTER FENCE. IT IS NOT UNIQUE, NEW, OR BETTER. I PROVIDED THIS FOR THOSE THAT
DON'T ALREADY HAVE A FENCE OR A DESIGN. THIS DESIGN IS INCLUDED FREE OF CHARGE FOR YOU TO DO WITH AS YOU
CHOOSE.
MATERIAL PRICES:
(5) Sheets ½"(12mm) A/C Plywood $32.99es $164.95
Misc, Nuts, Bolts, Washers, Screws,Plastic T-knobs $25
Material total $189.95

TOOLS:
Milwaukee 5625-20 3 1/2HP Heavy Duty Router $287.16 [Link]
milwaukee_5625-20_3-[Link]?
utm_source=scGPS&utm_medium=cse&utm_campaign=sc&scpid=2&scid=scsho1069001

Woodpeckers Phenolic Router Plate $64.99 [Link]

[Link]
Note: This plate is listed for the PC 7518, but fits the Milwaukee and others.

Dewalt DW744 $499 [Link]

¾" HSS Onsrud bit ½" shank upcut spiral bit for bench dog holes $44.50 http://
[Link]/en/wood/[Link]?p=42891&cat=1,46168,46171,42891
I was unable to find a 20mm bit.

GLUE Plastic T-knobs are a few dollars each at the local hardware store, but I find them online and pay just
55 cents each when I buy 10 or more. I keep a good inventory of them in my truck as they come in
handy for jigs. [Link]
Knob. You need the larger ⅜" (10mm) for the bench, but the smaller ones work for the router
fence.

Festool screw clamps. I buy all of my Festool products from Bob Marino. He takes good care of his
customers [Link]

APRIL 7, 2013 ROUTER FENCE & MATERIAL/TOOL PRICES PLUS LINKS PAULK WORK BENCH II 11