Converting wood workbench to metal top

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Hey guys, I've got a standard DIY from the 'net 24x48" workbench built from 2x4s and plywood.  I'm wondering if I can safely adapt it to a metal top.  I say 'safely' cause I don't want it catching fire.  I thought I could remove the wood top, lay some square tubing around the perimeter frame to create a layer of gap between the wood frame and metal top.  Then lay & attach metal slats (4-6"wide each) or some C channel.I suppose that sounds pretty cheap but I'd hate to throw this workbench out.  It's been really good to me   I'm adding a new section of wood wall mounted workbenches to match some shelves I've built.  But I do need a metal welding table and figured I could re purpose this.I don't figure on this table moving much if at all, but I am considering adding casters.  It's got crap on the lower shelf that's heavy already (metal pieces & scraps, chains, etc) so when I do move it, it needs to move with just me handling it.  Will the 2x4 frame support the metal top?  I did build it sturdy so it's framed tight.Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:My workbenches are wood framed with metal tops and I have never had a problem. In fact mine are constructed with 3/4" cdx covered with a sheet of 10ga. layed right on the plywood. I have never had a problem burning the wood. No fires so far, even when i've welded stuff directly to the table top. Mind you that's a few tack welds only, i've never laid a big bead across it. Ian TannerKawasaki KX450 and many other fine tools
Reply:You are not going to raise the metal-top temperature to glowing red with wood underneath are you? Even if you get the top really hot, the chances are that nothing will happen because there is no access to oxygen in the air. I put a sheet of 1/4" over a wooden-topped table at work that gets welded on top of occasionally. It sure beats welding on the floor! The bigger problem is keeping the top free of stored junk. City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:Originally Posted by tanglediverYou are not going to raise the metal-top temperature to glowing red with wood underneath are you? Even if you get the top really hot, the chances are that nothing will happen because there is no access to oxygen in the air. I put a sheet of 1/4" over a wooden-topped table at work that gets welded on top of occasionally. It sure beats welding on the floor! The bigger problem is keeping the top free of stored junk.
Reply:I am just considering the worst case scenario, like using a rosebud torch right down on the table top.  When I cut my 1/4" sheet down to fit the table, I made sure to leave a border all around the perimeter to afford the use of C-clamps. In hindsight, I might have left more of an edge, so that I could use the full throat of the clamps rather than just an inch or two.I think your top will do just fine. City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:Wood workbench?  Sure.Wood workbench with a metal top (sheet metal skin over a wooden under structure or a metal 'plate' top on wooden legs/structure) ?  Sure.Welding and working with torches (fuel-air, oxy-fuel, plasma, whatever) get done on an all metal bench.I've already set the LAWN on fire from steel sparks from an abrasive cut-off saw (put out with a bit of stomping and some water), I sure don't need to light up a workbench inside a garage/shop.Will a wooden workbench absolutely catch on fire if you are welding on/near it?  No.  But it could.  It could be smoldering for a while and then finally 'catch' after you are all done and gone from the garage/shop.  It's just not worth the safety risk IMNSHO.  Welding and torch work get done on the metal workbench(s) -away- from combustibles.  Period.YMMV.  The best laid schemes ... Gang oft agley ...
Reply:You could cover the top with Wonderboard before covering with metal.
Reply:The concrete/cement board used for tile makes a good insulator. I often use a scrap to protect drywall or 2x's from torch heat while soldering pipes. Again you need to use basic common sense. Applying torch heat directly to the top is asking for trouble. Setting an item on the bench so you can tack things in place with a mig then welding not in direct contact with the top will most likely work. The big issue in a garage is that you spend a reasonable amount of time there after you are done as a fire watch. Stray skarks can find all sorts of cracks and crevices to hide in and start dust/ paper/ rags etc smoldering. If you do wood working in the garage this is especially dangerous. It's almost imposible to clean up ALL the sawdust and sparks and sawdust is a recipie for a fire just waiting to happen..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:I used old sheet metal racks from a large box truck to cover my old Formica topped counters in the garage. mainly use is just as a grounded work table, but have welded some dogs onto it. Oh, I also made a back splash from the shelves.I think one time I smelled some burning wood possibly from under there. Nothing was wrong though.Weldanpower 225 G7Ironworkers Local #24
Reply:The metal top might be ok, but I would pay attention to the corners and joints around the table under the top.  The trick is that a red berry might fall into a corner between a leg and support for example and sit and smolder, waiting until you leave the garage before it lights up.If you are doing light work, might be worthwhile just building an all metal table to avoid the silliness.Hobart LX235Victor 250 Oxy-Acetylene Rig (welding and cutting)Bobcat 773F-350, 1999, 4x4, 16' 10K# trailerOutdoor Wood Burner - 10 cords/year
Reply:yer more in danger of catching other stuff on fire than that wood bench with a piece of sheet on topEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Thanks for the thoughts guys.  I won't be using a torch in my little garage here.  So no danger of that lighting anything up.  As for grinding and cutting sparks, I've done an ok amount of that in there already on that table and I've had no problems.  As it is I use a Dremel & Die grinder and those things rotate in the direction to throw sparks on me.  So far I've been a decent flame retardant.  I'll look into that cement board..  Sounds like it's pretty useful around the garage.  That might take care of those hot little pieces.Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:Have a tin shop cut you a piece of 14Ga and break the corners down and you should be good to go Monica. Angle grinders burn more stuff down in a year than welding and cutting does since it started.Big however here! If you are smart, 1/2 hour before the room goes dark... all slag, rod ends, dust etc. gets swept into a pile and left there. Give the area a good look and lights out. It's just a good habit.Matt(edit) Oh and the broom stays in the middle of the room near the pile...Last edited by Matt_Maguire; 05-04-2011 at 08:00 PM.
Reply:Sweepers, a goood sweepdown fore and aft, is a good habit and mkkes your shop a pleasent place to walk into.  Also you won't have to apologize to any unexpected surprise visitor as you open up.I offer three choices: Good, Fast, & Cheap. You may pick two.Hobart AC/DC StikMate LXHarbor Freight AD HoodHarbor Freight Industrial Chop SawDeVilbis 20 Gallon, 5 HP Compressor
Reply:A good sweepdown at closing will make your shop a more pleasant place  to work in and will keep you from having to apologize to any unexpected visitors as you open the doors.You only get one chance to make a first impression.I offer three choices: Good, Fast, & Cheap. You may pick two.Hobart AC/DC StikMate LXHarbor Freight AD HoodHarbor Freight Industrial Chop SawDeVilbis 20 Gallon, 5 HP Compressor
Reply:Originally Posted by Matt_MaguireHave a tin shop cut you a piece of 14Ga and break the corners down and you should be good to go Monica. Angle grinders burn more stuff down in a year than welding and cutting does since it started.Big however here! If you are smart, 1/2 hour before the room goes dark... all slag, rod ends, dust etc. gets swept into a pile and left there. Give the area a good look and lights out. It's just a good habit.Matt(edit) Oh and the broom stays in the middle of the room near the pile...