Torsion Box

If you question a person like me to define a torsion box, the moment you pose the word in front of me, I might most of the times turn comical in answering woodworking questions. Probably I may literary break the two words into another two separate words and simply create a mess altogether. So to avoid getting into all that mess with me, let's come straight to the point of knowing first what's a torsion box?

Define: Torsion Box

A torsion box is built by two skins applied to the original core material which practically consists of some type of wood, grid or framework. It is a superb concept of creating wooden tables, structural steel beams or as a matter of fact airplane wings. A torsion box is any day lighter than a heavy, solid beam weighing the same size and costing cheaper than a solid lumber. It is proven as an excellent resistance to sagging, bending or warping the instruments.

A torsion box construction is pretty simple and unproblematic for a common woodworker to work with. As there are two components consisting of two plywood for the top and inner core grids, all the dimensions and measurements would vary depending on the requirement of the project. The rigidness of the torsion box comes from the stiff locked plywood on each other and also the filler used in the structure. To carry out any easy woodworking projects one definitely needs a viable torsion box workbench to work on. Every plywood you cut, every nail you hammer in, every wood you trim would need a stabilized foundation. That stability would be availed from a workbench and no other. With this piece of information you must have got the indication that I am going to give you the simplest method of knowing how to build a torsion box (extension table). You are certainly good in a guesswork! This is a mobile based extension table, where the construction of a huge torsion box is going to act as its base platform. So here are some instructions for you to follow:

Building an Extension Torsion Table

Materials

    * Tape Measure
    * Safety Glasses
    * Wood Glue
    * Screws
    * Sheet of ¾'' MDF (medium density fiber)
    * Straight Edge
    * Sheet of ¾'' Plywood

Instructions

1. Step: Wear your safety glasses before commencing any woodwork.

2. Step: Now measure the width of the table saw, which is going to be the total width of the extension table.

3. Step: Also, measure the height of all the four corners of the saw to ensure its shim levels.

4. Step: This step will include the construction of torsion box. Build a 2'' thick box down to 16'' deep approximately. The torsion box is the frame made from the MDF strips measuring 16'' at its center. The two pieces of MDF are squeezed in between each other, glued and nailed consequently. You can relate the built of this box exactly to your house wall. The box is going to be firm, solid and will have a flat table top.

5. Step: Now is the time to build the table's four legs for support. Cut 4'' strips of ¾'' plywood that will need 8 pcs of the total height of the saw minus the ¼''. Glue both the pieces together by the length in the shape of an L.

6. Step: Attach all the legs to the torsion table using screws and glue.

This way your table is ready for all the future woodwork projects you shall undertake in the future. Also, note that a torsion box shelf can be fabricated within the table itself for further convenience and storage of hand tools. And not just one shelf, but number of shelf slots you can create for the easy location of tools.

Generally a strength of torsion box highly depends on how the grid joints have got glued to each other. If the nailing or screwing of the plywood is performed well, the torsion box will stay firm. But did you know a torsion box could be built using aluminum honeycombs or cores of cardboard as well. All the fuss about the filler contributing the stickiness to a woodwork isn't the sole reason why a torsion box stays stiff. If you see to it, honeycombs are even more fragile than a leaf in autumn!