Buddy PowerStick Work Surface Improvment

[erik_f]

I know there is another thread out there to make a lighter PowerStick work surface, but since I'm looking at the 8' PowerStick, I've been trying to come up with some ways to improve the flatness of a 4x8' work surface. What I have come up with so far is taking some structural extruded aluminum (like that used in the PowerStick and frame of the buddy) and just simply bolting a 8' strip down each side of the plywood work surface. The idea being, with the PowerStick down the middle and an extrusion on either side, hopefully it would create a nice flat 8' moving table. The concern now being, would the weight of the extrusions bow the table in the 4' direction. I now I'm trying to figure out the best way to put extrusions across the 4'direction without interfering with the drive system. You guys think this would help...or just a waste of time and money?

[jporter]

I used 3/4" Baltic Birch (60"x60") and cut a 36"x60" section for the table and used the remaining 24"x60" piece for the spoilboard. All seem to work well. However, if I ever need ultimate accuracy and the piece will fit my original 24"x32" table, then I have provisions for sliding the PowerStick off and the original table back on. So far, with the BB table, my work has been dead-on and no complaints. joe

[Gary Campbell]

Eric...
If I had to make a table as you describe above, I would use a combination of lightweight aluminum extrusion, honeycomb core material, very thin sheet aluminum, fiberglass mat and one of the high end epoxies, such as West Systems.

Construction would be of an odd number of plys of dissimilar materials, balanced from the center out, that we would layup and put in the vac bag overnight.

These layups are usually so strong and light that the extrusion does little more than protect the edges.
Gary

[erik_f]

I would love to have the know how to be able to pull something like that off...I suppose the only way to get it is to try. I know if I have the resources to pull it off either. Do you thick a layman could pull it off...I don't have a vacuum bag system either. I have seen your set up on YouTube and it always amazes me, Gary.
Erik

[Gary Campbell]

Erik...
Boat builders use a product that is called locally Nyda-Core. It is a composite honeycomb core with a fiberglass sheet on each side. Super strong, super light. You can epoxy most anything to it. If you can find the sheet, then you can just add your edges & drive component reinforcements.
Gary

[erik_f]

I will see if I can find some or something similar locally. There is a plasics dealer that could maybe have it or at least send me in the right direction. How much could I expect to pay for a sheet?

[Gary Campbell]

Eric...
I would look at a fiberglass or boat building supply store. The product should be available under a few different names and thickness'. last I remember, it was about $200 for a 4 by 8 by 3/4"
Gary

[erik_f]

I don't know of any around me...I'm in Central New York...but I've never really looked either...In the mean time...do you think that going with extrusions on the edge of some good ply would have any noticeable value?

[mikeacg]

Gary,

Thanks for the heads-up on Nyda-Core. I'm in a good area to buy boatbuilding materials so I think it should be easy to find. With the humidity around me, I'd really like something that wouldn't swell or warp.

Mike

[Gary Campbell]

Eric...
my own personal opinion is that wood products will warp or swell with humidity and/or temperature. I wouldn't use them.
Gary

[erik_f]

And, Upstate NY goes from 4 degrees and no humidity to 60 degrees and 50% humidity in a day during spring and fall. Either freezing or sweating in the garage!