A few years ago I built a building/assembly table for a buddy. I used one sheet of 96" X 48" X 1" furniture grade plywood cut in half to make a 48" X 48" table. Between the sheets I used some 1-1/2" square aluminum tube. This provided a very stout, straight table, heavy table - perfect for building and assembly for most sport planes.

To build the table up I drilled holes through the aluminum tube for a fastener to pass through, and on the bottom side of the aluminum tube I enlarged the hole for the fastener head to pass through. Running the fastener up through the bottom of the top sheet eliminated any fasteners on the top surface. Next I prepped and spread epoxy on the aluminum tube and then screwed the aluminum tube to the bottom side of the top ply sheet. After that I spread epoxy on the aluminum tube then attached the bottom sheet screwing through it and into the aluminum tube.

This table so far has resisted any sign of wanting to warp or twist, and the weight is enough to keep it in place if any hammering is done on it.

The same principle can be applied by using a thinner piece of plywood and even some angle aluminum stock. Extruded aluminum stock will go a long way in preventing the wood from warping or deforming.

Hogflyer