I'm in the process of building a torsion box and need some advice on how to attach the frame to the top using 1/2" plywood. I'm considering pocket hole screws for this, but I'm a bit worried about the thickness of the plywood and whether it will provide enough strength. What are the best methods or techniques for joining the plywood securely?
3 Answers
If you're looking at using butt joints and glue, that should work just fine! Just make sure you clamp it down properly while it dries. Personally, I might opt for 1/4" dowels instead. I've found that when you get dowels tight enough, they can hold together well without needing glue. Plus, it's handy if you want to take the top off occasionally. You could even add some locking hardware underneath for extra stability. I made a similar table for my cycling setup, and it's solid yet easy to disassemble when needed.
Having a spoil board on top sounds like a great idea for protection! And yes, don’t forget there should be supports inside the torsion box, like a grid of beams to help with load distribution. Those will help ensure the top and bottom stay attached nicely. Also, Kreg says you can use pocket holes in 1/2" stock, but just make sure to choose the right size screw to avoid poke-through issues.
When I build with 1/2" plywood, I like to use glue along with butt joints and #6 x 1 1/4" screws. It's worked for me so far; nothing has fallen apart!
Thanks for the tip about supports! I’ll definitely consider that.