Step 10: Cut List
A) Table saw
1) Because we a) wanted greater knee clearance under the work surface and b) had to clear a surface-mounted plastic pipe on the wall (it comes from the furnace humidifier), we ripped 2x4s on the table saw to get 2x1 3/4" stock.
2) We ripped the 4x8 plywood into 2 24" x 8' shelves
3) We reconfigured a 4'x4' (16 square feet) pegboard into a 3'x4' plus a 1'x3' (adding up to 3' high by 5' wide) plus a 1'x1' scrap.
4) The fire doors were different sizes, and added up to 13'6" in length, which caused clearance problems. On the table saw, we ripped them both to 28" deep and in one case, made a slightly unpleasant discovery: in the recent past, some fire doors now resemble drywall in that they feature a cement core. The saw made quick work of the cut, but the dust was extremely thick. After ripping the wood door to width and while it was still outside the house in the garage, we sanded off the old finish on the better side with an orbital sander.
5) We ripped scrap plywood to size for two shelves that were mounted above the workbench: a laptop shelf was 13"x24" and a shelf for tape measures and other items that didn't hang well on the pegboard measured 6"x12".
B) Chop saw
1) For the 12' shelf rails, we used an 8-footer plus a 45-inch piece. Combined with two end pieces at 1 1/2" apiece, that adds up to an even 12 feet. Some 45-inchers were the ripped 2x4 while others were full with 2x4s.
2) The end pieces (6 of them) were 25 1/2" each, spanning the 24" of the shelf plus the front leg on each side.
3) At roughly the 4' and 8' marks of the rails, we included a cross brace so that the plywood shelves could join on a solid surface. These pieces, 4 in all, measured 21" (24 - (1 1/2x2)).
4) 2 front legs at the corners were 2x4s cut to 36". The middle legs were 2x6 because the rails needed a base on which to join. Technically we only needed one 2x6 but we used two for symmetry.
5) To support a computer shelf on the wall above the work surface, we mitered 2 2x4s at 45-degree angles. In addition, we cut 2 12" 2x4s, one as a screwdriver rack and the other as a cleat for the tape measure shelf.