The Torsion Box Platform

Ever wondered how airplane wings are structurally designed to attain their rigidity and strength? And yet be light enough so that its own weight is not a liability to flight and fuel. The torsion box design makes it possible; and in woodworking, this offers many possibilities to build a platform that is lightweight, strong and extremely rigid. And, surprisingly easy to build.

All beds in our house were made with torsion box platforms (see other beds made the same way in "my personal story". Click picture to enlarge.

Same structure made for a very sturdy, light weight bench (you can pick this up with one hand), shown below:

All of these structures are practically air inside, thin skin over a grid structure. It is this design that makes for a much lighter weight compared to a comparably dimensioned solid wood, yet it is much more rigid and has a higher strength to weight ratio. The above projects used quarter inch oak plywood.

Below is a half day project. From your nearest home center, 2 pieces of 2X4 hardboard (tempered) and three pieces of 1X2X8 premium pine will cost about $25.00. Lay out one of the boards flat and cut to dimension the 1X2 pieces as shown:

From the original "basic woodworking tools", the only additional tool needed is a brad nailer kit (available with compressor, air hose and other accessories). Worth having for under $150, since the compressor alone can serve many functions and the nail gun will have other special applications. Of course, one may use screws to fasten the boards but they need to be counter-sunk and glue is still mandatory. And it will be a slow process.

The spacer blocks are very useful for laying out the grid for ease and consistency.

The key is to sandwich the grid with the two thin skins of hardboard with glue and small brads. Lay out straight lines with chalk to guide you where to drive the brads.

The finished project is light but so rigid it will not even flex or bend under heavy load. And because of its light weight, it is very portable and makes for a reliably strong temporary workbench, or for other platform functions. Stores out of the way for very little footprint. Project was done in half a day.