Tape, Square, Level
Miter Saw (Chop Saw)
Cordless and Corded Drill
1/8 inch drill bit and 3/16 spade drill bit
Ratchet and Socket
See attached Excel Document
Also used several 2.5 inch Coarse Thread Wood Screws
Step 1: Step 1. Cut Lumber to Length
Second, cut (4) 2x4s to 69" in length.
Third, cut (4) 2x4 pieces to 30" in length.
Fourth, cut (10) 2x4 pieces to 27" in length.
Last, cut (8) 2x4 pieces to 3" in length for frame support until the carriage bolts are tightened down.
Step 2: Step 2. Construct Upper and Lower Frame
First lay out the 2x4 pieces you cut to length in the last step in the same configuration as image 1. Make sure everything fits nice and snug.
Next pre-drill and fasten the corners of the frame where the 69" and 30" pieces come together.
Once you have the box made, supplement this box with a 27" cross member 3 and 9/16" from the inside of the 30" ends...like image 2. Image 3 shows how I made sure the frame would be snug up against the 4x4 legs. I would dry fit the 4x4 leg into its slot before fastening these 27" members.
Lastly, add the remaining (3) 27" cross members to the frame at even intervals between the previously added members.
Repeat this process for a second frame. Should look like image 4.
Tip: If you have two drills (cordless/corded) or a quick change driver set use it. Here I used my corded drill to pre-drill where I intended to fasten the joints to prevent splitting. Then I would use the cordless dewalt to drive home the 2.5 inch wood screw...much quicker this way.
Step 3: Step 3. Add Temporary Supports to Leg Members
Step 4: Step 4. Assemble the Desk
First I laid the lower frame on the ground as a base and as way of keeping the 4x4 legs from falling over. The legs did not fall over because they fit so snug into their respective slots.
Next, I carefully lifted the upper frame above the legs, centered it, and slowly lowered it until it fit right over the top of the 4x4 legs. The fit was tight so I used a scrap piece of wood and hammer to strike the upper frame into position. I tapped the frame at each corner, iteratively, until the frame was resting flush on the temporary supports.
Once the frame was at the desired height, I needed to drill the holes where the carriage bolts secure the frame to the 4x4 legs.
Once the holes are drilled, put in the carriage bolts, the washer and top it off with the hex nut.
After this, I flipped the whole desk over like image 9 and tapped the "bottom" frame (now on top) down until there was 2 feet of space between the top and bottom frames. Then I repeated the drilling and fastening process executed on the top frame.