Folding Bench Top Extension Made From Recycled Bed Frame
Introduction: Folding Bench Top Extension Made From Recycled Bed Frame
I recently reduced the length of my work bench to better fit my work area which was nice since I could move around it more easily. It has worked out great for the most part but whenever I work on larger or more complex projects I realized I need more horizontal space. So I decided to make a fold down extension to my bench top that could be stowed away when not in use.
I used recycled bed frames to make a frame to hold the extension bench top. I liked the idea of having a metal frame so that I could switch out the top if it gets to beat up and worn out with out having to build everything from scratch again. If the extension top gets too damaged I can just unscrew it and replace it with another one. The actual extension bench top is made from two pieces of compressed particle board that a friend of mine was throwing out. Before he threw them in the trash he texted me to see if I could use them. At the time I didn't have a real use for them but they were free so I went by his warehouse and picked them up.
I only had a vague idea of what I wanted so this is more of a design/build type of Instructable. Also the dimensions I used are specific to my bench this would most likely need to be customized to fit your personal space.
Supplies
Bed Frames or Angle Iron
2 pieces of 1/2" x 18" x 36" inch particle board or plywood
Circular Saw
Straight Edge
Clamps
Angle Grinder with cut off disks and flap sanders
Welder
Drill
Drill Bits Various Sizes
Wood Glue
50 pack 1 inch screws
Door Hinges
6 - 2 inch wood screws
4 - 5/16" lag bolts with
6 - 5/16" Washers
2" x 2" x 18" piece of scrap wood
Black Spray Paint
Step 1:
This is a picture of my bench. The second picture shows the particle board leaning against the bench, its sort of my mock up to see if the sizing is right. I didn't want the particle board to touch the floor so I decided to cut it shorter.
Step 2:
I decided to make the extension 32 inches long. I have some scrap wood to lift the pieces off the floor and then clamped the two particle board pieces together. Then I used another piece of scrap wood as a straight edge and my circular saw to trim down the two pieces.
Step 3:
Next I liberally spread wood glue all over one piece of the particle board. Then I placed the other piece on top and predrilled some holes and screwed it together. 787
I could have clamped it together and let it dry overnight but I was a little impatient and decided to screw it together instead.
Step 4:
A few weeks ago someone in a nearby neighborhood was throwing away several bed frames and posted a "curb alert" on a local neighborhood app. They were free for the taking and sitting on the curb in front of their house so I drove over and picked them up. I didn't have an immediate use for them but its good steel that's free so I couldn't pass them up.
Bed frames are great but they do come with a few extra pieces that need to be removed which is no problem for an angle grinder with a cutoff wheel. Most of the attachments are sort of pinned or riveted in place. To remove them you just cut off one side of the rivet. The more flush to the bed frame you can make the cut the better. Then hammer out the remaining piece of the rivet. Some times you need to use a steel drift to knock out the pin, if you don't have a drift then a scrap piece of round bar or a old/dull drill bit will do the job as long as it is smaller then the pin's diameter.
Sometimes if you don't need the full length you can just cut off the extra bit which saves time but waste material.
Step 5:
I cut all four pieces of the bed frame slightly larger than the particle board by about 1/4 inch. So the longer pieces of the frame were 32 - 1/4 inches long and the shorter pieces were 18 - 1/4" long. This allows me to account for the thickness of the angle iron for the welding portion of the build. I also decided to notch both ends of the two smaller sections so that I could get flat seams when I weld the pieces together.
Step 6:
Full disclaimer: I can't weld. But I do have a welding machine. My welds are not pretty by any means but the are good enough to stick the pieces together. I made sure to weld all the inside and outside corners. 220