How to safely rip 2x12 lumber without a table saw?

[Matt Radtke]

Jared,

If you don't have a table saw, I'd suggest you pass on ripping 2x12s and up-scaling a bit. Get 2x6s. All you have to do now is worry about getting the corners down. If you're crazy enough, you could even glue them up as is and hand plane them flat when your'e done.

That said, I made my top out of 2x12s and had no problems. My approach was to buy the longest and best stuff. Did exactly what you're planing and it works fine. 4 years (or 5?) later, it's perfectly adequate. It was, however, a Imperial crap-ton of work.

I do have ambitions to make a new bench to make improvements in design (different tail vise, different joinery from top to legs, probably skipping the tool well, blah blah blah) and will not laminate the new top. I'm getting the biggest stuff I can and am shooting for no more than 3 glue joints in the top.

[Rob Feldner]

I made my benchtop out of 4 layers of 3/4" plywood, laminated together into a beam. It is still flat, solid, and sound, after about 10 years.

If you are wanting to laminate a 2x4 on edge, I would use a jointer to remove the rounded edges. Or, if you don't have a jointer, use a straight edge and a router to do the same job. Might need to make a jig to hold it, but could do it with a standard straight edge.

Doc

Since it sounds like you are fairly limited tool-wise, this is probably your best option. If weight is an issue, or if you want to use a bit less material, you could build a torsion box. I could go into a long explanation that might end up clear as mud, but just google "torsion box" and you'll get the idea. Its something that is very doable with a circular saw and very stable.

[Michael Moscicki]

While not what you probably wanted, but given the tools you have this may be the best and least frustrating option for you.

Here are some options from Woodcraft:

24" x 60" Laminated Maple Bench Top, 70 Lbs. - $219.99
http://www.woodcraft.com/product/2005134/4966/24-x-60-laminated-maple-bench-top-70-lbs.aspx

Birch Workbench Top 1-1/2" x 27" x 60" Sale! $99.99
http://www.woodcraft.com/product/200...x-27-x-60.aspx

The maple is more expensive but it also comes in more sizes.

Grizzly has a lot more sizes available than woodcraft and at more competitive prices. It also has some oak workbench tops.
http://www.grizzly.com/catalog/2013/Christmas/39