Workbench - Part 1: Metal work
This is the first installment of a series on how I built my workbench. This first article is about metal work. You will find that it is a lot easier than you might think.
Here is all the required material. A round steel rod 30mm in diameter. Three metal plates and some flat strips plus 1m of ACME threaded rod (about 18mm in diameter) with two nuts.
To start working you will need a angle grinder with 3 different disks: A very thin cutting disc (1mm thick), A thicker grinding disc (3mm or more) and a sanding flap disc.
Start by preparing two of these flanges.
Use a template to get the right shape. Use it to draw the shape of the two required flanges on one of the metal pieces. Punch the location of the three holes.
With the angle grinder and the thin blade cut them to rough shape. You only need to do straight cuts.
Use the thicker grinding disc to obtain the final shape. Smooth the edges with the sanding disc or with a metal file..
Drill the three holes with a metal bit using a drill press. Start with a 4mm diamter bit and enlarge to the required diameter. In my case it was 6mm. Deburr and countersink the holes if necessary. The central hole should be smaller than your ACME rod. We wil comment on this later.
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