continued ...
This drawing shows the assembled bench and provides a key to the location of the various parts. You can modify the bench to suit you or your club’s special needs. (Click on photos to enlarge.)
These are all the individual parts that are combined to make a safety bench. Notice that all the required dimensions are included.
This is the parts key for the bench-top assembly, which is depicted in this drawing.
This is the parts key for the side view of the safety bench.

Assembly: We built five benches at a time and made templates of all the pieces to be used for building more tables in the future. The wood for all five tables was precut.

Construct the bench tops first. Predrill all screw holes with a 7/64 drill to prevent the wood from splitting. Lay the 2 x 6s over the two 2 x 4 crossbraces. Note that the rear crossbrace is inset the width of a 2 x 4 on each side. After spacing the top pieces evenly, insert one screw in each corner of the top pieces. Square the whole thing with the framing square, and screw in the other screws on each piece. Use two screws on each end.

After the top is constructed, add the horizontal spine centered under the middle, long 2 x 6 top piece. The spine must be notched where it meets the rear crossbrace. This notch does not have to be precise; it can be cut with a Skil saw then knocked out with a hammer. Make several cuts before knocking it out. You can use a chisel if you prefer. Use six evenly spaced screws to fasten the spine.
 


Why not make this a priority club project this year?


Add the 2 x 4 front legs. Use two screws on each. Draw guidelines across both legs at 26 inches and 271⁄2 inches. The legs are attached 10 inches back from the front of the top and with the top centered between the guidelines. Make sure the 26-inch length is toward the bottom.

Turn the table upside down, and add the 1 x 6 x 24 field-box supports. These should be butted against the spine and back against the leg. Use at least seven screws on each support. Add the 2 x 4 angled side braces next with two screws on each end. Make sure to square the legs before screwing in the braces.

Add the front 1 x 4 angled braces. Screw in the bottom of the front one first, then square the other leg left to right before screwing in the top screws. Repeat with the other brace.

The rear leg is attached by butting it against the spine end. Use two screws in the spine. Add the short 2 x 4 angled brace in the same manner. Attach the 1 x 4 small angled braces on each side. Turn the table right-side up. Insert three more screws through the middle top piece into the rear leg and two screws on each rear comer of the top into the 2 x 4 angled brace that was previously installed.

Attach the 1 x 4 topside rails on both sides. Use a piece of scrap 1 x 4 as a height guide. Add scrap carpet to the airplane wing restraints using 1/2-inch T-50 staples or 1/4-inch roofing nails. The carpet protects the wing from dings while the airplane is on the bench.

Variations: We built a bench for Giant Scale airplanes by lowering the top height by seven inches and extending the center top piece by six inches. The 2 x 4 leg/restraint lengths are not changed, so the restraint height is increased by seven inches. The rear leg is 19 inches. If a wider top is needed to accommodate wider landing gear, additional top pieces can be added. This Giant Scale bench is well liked.

Wheels can be added to the front legs so that one person can move the table more easily. If wheels are added, the rear leg will have to be extended to make up the difference of the wheel height.

Cup hooks on which to hang a transmitter can be added to the edge of the bench or the box supports. Why not make this a priority club project this year?

Back