Polyurethane workbench...help me build it?

Question

I'm about to finish my workbench and I need some advice. Everything is finished except for the top... I'm thinking of laying down a thin plywood and then on top of that a nice 3/4 inch oak or poplar plywood. My question- if I attach some molding all the way around and then just pour and fill the top with polyurethane would it just make a mess? or would it dry and give me a nice thick clear coat? please help....

Answer 1

good to hear you want to put a finish on your work bench, personally I always do, not that I care about its looks, more than the functionality of it.  cleaning glues and water off your bench is so much easier.  

put several thin coats of poly on it let it dry  lightly sand with fine sand paper, keeping in mind your not after looks more than the rougher surface for the next coat to adhere to.  

then when it gets bad, a little sanding with sander and you have a nice surface again.   i use my bench daily  and put  several  more coats of poly on it once a year.

Answer 2

You said it is a "work bench". It will get scratched and nicked over time so why bother with the fancy coatings (thick poly won't work)? I have benches with tops made of old doors, steel and wood.

Answer 3

Polyurethane (and all varnishes, for that matter) don't "dry" - they cure by reacting with oxygen. If you try to pour on a single thick coat, only the top will cure, and you'll end up with a soft, sticky mess. Also, poly is durable, but it isn't hard, even when fully cured, so it'll get scratched easily, as already said.

If you're set on using a thick, clear top, look into "pourable bar top coating". Otherwise, an easily-replaceable sacrificial top is the way to go, as said.

Answer 4

Well my first concern, this being a work bench, is after it set it would get scratched and start to look worn very quickly. I would just lay down either cork board or some cheap form of OSB thats easy to replace if it gets too damaged.