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I'm planning on making a replacement for our large work desk (about 180 x 90cm). I've done a fair bit of woodworking but I don't have the space, facilities or skill to glue up a large table top to be nice and flat. So I was considering buying a large section of solid wood worktop, cutting to size and making legs.
Just a little concerned about strength. Would a 40mm section of solid worktop need stretchers/aprons to keep it flat or for strength? I quite like the minimal look of just the very top of the table so would be nice not to have to add them. Or should I consider routing grooves for some steel flat bar? Will it be perfectly strong enough on its own?
Is the original table borked?
Could it be used as the base for the new top?
How good does it have to look?
It's a good plan to make a custom table easily. You can also but lots of legs as well so worth googling. Yes it will need additional support. If you want to minimise the visual impact you could inlet some c channel. However the problem is at only 40mm thick you will not be able to have very deep c channel.
Original table is fine, but isn't a looker. This new table is primarily to have something nicer looking.
C-channel sounds promising. This is essentially a big desk, so isn't going to be under tons of stress. Would you put c-channel across the way (i.e. 3 or 4 short pieces) or length ways?
I would go length ways, but with across ways near the end. Basically replicating having rails / stiles but because the table is so thin I would want third length ways along the middle. This is all just initial thoughts! Again at 40 mm it feels a little thin to inlet some good depth c channel. I think I would have a extra layer of material underneath (some good ply maybe) that doesn't come right to the edge and painted Matt black so it will no show. () Then you can inlet some deeper c channel. Hope that makes sense hard to explain
Yeah, makes sense, thanks. Current table is similar in design with just a top without any supports except a 20mm wooden batten across near each end. But it is full length strips laminated together, unlike the worktop I'm looking at which is lots of short pieces laminated.
I'll look at using some c-channel. Should be within my capabilities and provide some extra strength. originally considered making legs from scratch, but seen some decent looking tapered oak legs with a chunky metal plate that just bolt on which would be easy. Making big stuff in my wee shed is tricky!
40mm isn't thin!
You'll struggle to lift that at that size.
If it were 18/20mm thick I'd say that's a bit thin but 40mm is a chunk.
I've just made a 4800mm long table which was 38mm thick and had fairly minimal supports and no underframe as such.
You could park a car/dog on it 😊
It was made in four sections, each one measuring 2400x800mm so longer than your desk. I could only just lift each section myself and I'm rock! 😉
At 1800mm long/wide and 40mm thick, I wouldn't be all that concerned about not having an underframe, unless your laptop is like WELL heavy.
It may sag a little over time but all those glue joints in a worktop are incredibly strong. Possibly more rigid than wood alone arguably. The added benefit of that style of construction is also that it tends to be less prone to warping because of all the glue joints
Put the legs as far inward as you can to lessen the span and you could always add a beefy batten at the rear, underside of the desk which would be fairly discrete. Maybe some kind of metal angle painted for added rigidity at the back instead, although I don't think you'll need it personally.
Be aware that any C-section or anything you bolt/screw in across the grain needs to be slotted to allow for timber movement.
Whatever finish you apply, apply it underneath too for balance.
Pics when you've done it 🙂👍
Thanks Kayak. Your table looks incredible 👍
That gives me a bit of confidence. Probably not going to happen for a few weeks but I like to have it all worked out before starting! Will return with pics!
40mm isn’t thin!
I'll bow to your experience, I am a fan of massively over built so 40mm over A 1800 span seems thin for me. I build my tables more like workbenches!
(probably because I end up abusing them like work benches)
Currently sat at my desk which is exactly as you are describing 40mm thick oak staves, 1800mm long, 730mm depth. It is held up at on the right hand end by a 500mm wide drawer unit and at the back and left hand end by brackets attached to the walls. It has no additional bracing 'cos it really isn't necessary. It has sat here for the last five years and has not twisted or bowed at all in fact id have been amazed if it had. I have rather a lot of stuff on it, in fact time for a tidy up. Probably no more than 30 kilos, books, printer, computer and a 1.8kg jar of jelly beans (or at least it was).
If however I was going to be using it as a workbench or sitting weights of 60 kilos plus on it on a long term basis then yes I would include bracing.
I have a 1.8m long desk made out of scaffold planks I planed and dominoed together. It's rock solid and I can sit in the middle and bounce. I woudn't worry too much!
unless your laptop is like WELL heavy.
I had a bespoke desk made years ago (Ash with ebony inlay) and it was braced specifically for 2x 21" CRT Sony Monitors at 45 kg each!
How things have changed with LCD monitors weighing bugger all...
There is a useful website for calculating deflections in spans (although I've never really used it in anger) called The Sagulator.
I've just entered the dimensions of your desk in oak, and with a 100kg weight dead centre, it suggests there's nowt to worry about 🙂