benchtop material for extra long bench

[Jim Barstow]

I'm building a mini-shop in my garage separate from my full sized away-from-the-house shop. I've got
10' of 30" deep floor cabinets against one wall which will form the base of the bench top. The question is,
what can I use for a bench top that I can get in 10' lengths and doesn't cost a fortune? If it were only
8', I'd use multiple layers of a high quality plywood with a solid wood edge. The 10' length is a problem though.

[Aleks Hunter]

If you live near a major city, there are plywood manufacturing companies that routinely make 10' long plywood.

If you want something more substantial, think about a salvaged bowling alley lane. But use a metal detector before cutting.

[Jim Neeley]

Jim,

As long as plywood works, you could use multiple layers and stagger the joints between layers. For example, use 5 layers of whatever thickness and make the two pieces:

Layer 1: 2' + 8'
Layer 2: 4' + 6'
Layer 3: 6' + 4'
Layer 4: 8' + 2'

It would take 5 sheets of ply to give you 4 layers of thickness, but it works.

Jim in Alaska

[Sam Puhalovich]

Depending on how you'll use the top; just get some pine 2xs ... even-them-off on the planer ... then cover with a piece of masonite.
Top-it-off with about 4 coats of a 50/50 mix of turpentine and poly.

[Matt Day]

Can't you have some intermediate supports to the floor?

[Jamie Buxton]

Many lumberyards stock ten-foot exterior sheathing. Think about it -- the interior height of a room is eight feet. Exteriors sheathing would want to cover the eight feet plus floor joists, ceiling rafters, and overlap on to the foundation. That gets you to needing ten-foot sheets. Okay, sheathing is usually roughsawn, so you may want to put a smoother top layer on the bench. But you can at least make the structural part ten feet long.

[Prashun Patel]

Consider making (2) smaller benches (2x5 or 8+2) one or both on locking casters. This will give you all the support you need and will allow some flexibility on configuring for eccentric support.

[phil harold]

http://www.trustile.com/

http://www.vtindustries.com/doors

pretty much any real lumber yard should be able to order them

[John Sanford]

You may also be able to salvage the decking from a 10' or longer utility trailer.

[Todd Burch]

There's a lumber yard in Houston that stocks maple butcher block countertops in long lengths, I think up to 12' and 36" wide. I've seen them @ 30" wide. Check your area.

Considering the thickness and durability of this top, and it's already glued up, it might be a good solution to your project.

[Ole Anderson]

Depending on how picky you are with your work surface, my local cabinet supplier stocks and sells retail 36" x 144" x 1-1/8" particle board (used for counter tops). Edge it with hardwood and give it a few coats of an appropriate sealer and you are good to go. That stuff is awesome, but you better have help moving it around.