Go to the local timber merchants and ask if they have any cover sheets, has been a while since i bought any but expect to pay maybe $10 or 20 for a full sheet of 12mm + MDF
These are the top pieces that are used basically to protect the sheets underneath, they are usually less than perfect as in have the odd scrap or gouge on the edge but totally fit for purpose for what you want
Quick update, I stopped being so tight and bought some plywood. No more wobbles, so thanks for the advice.
One more question. Do I need to paint the plywood to protect it? I have a small pot of acrylic paint which might cover it. I also have some varnish if that would do it?
Now I'm considering using the offcuts to create half a side (at the bottom ) to make it even more rigid, and look a bit better.
I'm not sure about covering the entire side because it might be handy to use clamps on the top part.
Any other advice would be greatly appreciated. Thanks
I wouldn't cover the sides - makes getting at anything sitting on the shelf underneath a PITA.
Wouldn't really worry about painting it - it's going to get covered in muck, scratches, paint drops, etc eventually.
I would cover the top with some scrap MDF or something. If it's a proper workbench, you're going to be drilling, sawing, clamping, painting, gluing, etc, so something to protect the thin veneer of the door that you have used as a table top will help.
If you get a vice ( good idea !! ), http://www.bunnings.co.nz/irwin-light-duty-workshop-vice-112mm-_p00615857 mount it as close to one of the legs as possible, and with some left over ply sandwiched between the vice and door, - there is minimal support on the door veneer. A vice can be used as a mini anvil, as some have a solid cast iron plate behind the jaws. Found it handy on more than one occasion to bash something straight, or bent. If you mount the vice anywhere else, it will bounce like crazy when using the anvil .... My 2c.
Nice work. Moisture won't be an issue unless it's exposed to the weather e.g in a carport and even then probably fine. That said, if you have some hardwearing high-gloss paint it will make the whole thing look tidy and will make it easy to wipe down. I'd put a thick piece of mdf on top before mounting a vice. Of even better - triboard.
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