I was so impressed with the Ron Paulk Ultimate Workbench that when I saw his next creation, the Paulk Total Station, I knew I had to have one! This post documents the stages in making the PTS and you will notice that the Ultimate Workbench makes the process a whole lot easier. The PTS uses a similar build technique, the double layer hollow structure, but has a few nice twists, like the adjustable stops with a tape measure built into the bench which make cuts with the mitre saw quick and accurate. It also has the tubes build in to support a table saw.
Here is the schematic from Ron’s excellent PDF which shows an overview of the PTS
Ron Paulk’s schematic of the PTS (C) Ron Paulk
First I made a template to allow me to cut out the four legs
First Leg Cut
All four legs cut and the edges rounded off.
Experimenting with a jigsaw to cut large diameter holes.
A simple attachment provides a pivot point.
The result, quite pleased with that!
Cutting the template, two circles.
Here’s the result, a template for the sides.
Side piece cut.
Four spreaders cut with the template.
Front and rear cut with the template
Initial assembly. I used courtesy blocks to assemble the Ultimate Workbench but Ron found that glueing and screwing the joints was strong enough. Simplifies construction.
The base plus sides.
Front cut out for the Mitre Saw
Making the mount for the saw.
Make sure the height of the saw matches the bench top.
The saw is attached to a piece of ply so that it can quickly be fitted to the bench.
Saw mount from the front. It is held in place by a dado (slot) cut in the front of the base mount.
Fitting the bench top. the rear is fitted first then the pieces either side of the saw.
Glueing supports under the bench top.
Front of the bench top being glued.
The ‘bench dog’ holes are cut. These allow work pieces to be clamped to the bench.
Here is one of the support legs for the extension arms. It is adjustable to level the arms.
Adjustment knob made from a circle of ply with a nut pressed in place
Glueing the extension arms. These are made of two sheets of ply laminated for strength.
You can never have too many clamps!
Slot under the extension arm. This is to hold the adjustable leg in position.
Leg sits in the slot.
Adjustable stop set up
Adjustable stop flipped up. This allows the bench to used without disturbing a previously set position.
Tape embedded in the bench top. I used a cheap 3m tape which was pressed into a dado (slot) routed into the top of the bench. Silicon holds it in place.
View showing stop in relation to the saw. Stops can also be used on the other side of the saw.
No sooner finished… Here you can see the extension arm being used to support long timbers. Very useful!
Extension arm in use.
Working ‘chez moi’ making some gates
The bench is so quick and easy to set up anywhere.
Putting the finishing touches to some shutters.
Not a bad view from the office..! In addition to the mitre saw I also have a vice and pillar drill set up.