I ended up finding a 10" wide 4/4 board of southern yellow pine and claimed 72" to get enough material for all of it. I also needed a 6" wide 4/4 (1" nominal, usually around 15/16"), of roughly 69", and a 3" wide 4/4 board of 70 1/2". The size I made I could easily carry by myself. It doesn't fold perfectly flat, but it does fold up well enough to make it way easier to handle. Note that this bench is no modern engineering marvel. 2) I think it would have prevented the bench from folding up as nicely as it does now. It's lower than my shop bench, but one advantage to that is if I plane on it, more of my body weight will be pressing down, which should lower the stress left to right on the bench. I also planned in my sketchup to have feet on the bench to give it stability in width, but after I had the bench assembled, I left them off for two reasons: 1) I ended up liking the height without the feet. Which is good because in the process, I changed the dimensions and had to cut some new pieces (I don't recommend doing this, btw, it gave me several big headaches). I ended up only being able to find 8/4 12" stock, which gave me some extra (8/4 in rough cut lumber is 2" nominal, and usually works out to something like 1 15/16", unless you have a generous mill/lumber dealer). I figured up mine could be done with a minimum 89", according to my sketchup.
Roy claims you can get most of what you need for his bench with a 2"x10"x12' board.
That way I could also decide how much lumber I needed by virutally rough cutting my pieces.
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