I'm just finishing my bench now. I used a solid core 6' 8" (80") x 36" x 1 3/4" masonite door for the top. I used a 6' 8" x 32" x 1 3/8" for the base and I put castors under the small drawer units that form the end supports. I found that in just a couple days of the bottom setting on the castors, it sagged almost an inch in the center. I ended up putting angle iron (old steel bed frame) on each edge of the bottom door and again on each edge of the top door. I'm fairly sure this is going to hold up OK. I'll check straigtness before the first build though.

I have a couple 33% planes, a Laser 200 partially built and an Extra 230 kit, and old Ace kit. Those and my ASM P-61 have been waiting for a bench, my old desk just was't big enough. 36" width is long enough to hold the finished plane on it's landing gear. The 80" length is long enough to build a bigger wing that I'll ever use. My table top is going to be closer to 90" finished, with a glue box, light stand, and a Dremel flex shaft stand on one end.

Don