Instructables

Heavy Duty Workbench With Loads of Storage

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I set out with the intention of making a sturdy, reliable, and mostly simple workbench. As I was tired of not having a proper location to work on projects, or brainstorm creative solutions for existing problems.

A few years ago, I had a basic idea in mind of a large, long work bench with a replaceable work surface, a lower shelf and pegboard for tool storage/organization. Another design goal was to ensure I had the ability to break it down with relative ease when I eventually move.

I had a pre-existing plan in mind, but adapted the method of sandwiching the posts, and temporarily supporting each shelf from: http://www.instructables.com/id/Heavy-Duty-Work-Desk/

Materials:
Two (2) 4’x8’ sheets of 5/8” plywood
Three (3) 4x6x10’ treated wood posts
One (1) 4‘x8’ sheet of 1/4” pegboard
One (1) 4‘x8’ sheet of 1/4” hardboard
Twelve (12) 2x4x8’ boards
Twenty Four (24) 5/16”x6” carriage bolts
Twenty Four (24) washers
Twenty Four (24) hex nuts
A large number of 3” deck screws
 
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Step 1:

The first step is to cut sixteen (16) 36” segments from the 2x4‘s. You can cut each 2x4 twice, so this will require eight (8) 2x4’s. Next you need to cut off 38” from the top of each 4x6 post. Accuracy in this step is crucial as we’ll be using the 38” post as the front of our desk and the 82” remainder as the rear structure and the pegboard support.

Step 2:

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The next step is to build the basis of our frames, by attaching one 36” segment to the edge of two full length 2x4’s.
thirrrsty1 year ago
Hey, MG, this looks exactly like the type of thing I had in mind for my garage. What was the ballpark cost of this porject, if you don't mind my asking?
MusicalGenius (author)  thirrrsty1 year ago
I kept most receipts, and it came in around $250 after it's all said and done.
ccison1 year ago
Nice looking bench! However, I would strongly advise you to immobilize the surface of the pressure treated wood. PT lumber is an indoor health hazard, I'm told, because as it ages the coating becomes a powder that can become airborne (I've seen this myself).  The dust is a significant lung hazard, if I remember correctly (even the modern "safe" copper-based stuff, though some arsenic-based used lumber is still around). Given that the bench is already installed, I think it might be advisable to coat the legs with something durable and penetrating (such as water-based acrylic floor varnish; oil-based might work better). Whatever you chose, it should be several coats to make sure all the pores fully are sealed. I don't believe this should in any way interfere with the durability of the legs in a moist basement environment, if it should be stored there.  In my experience people keep workbenches for decades, so ample caution may be in order here.  Perhaps others can comment more knowledgeably than I.
MusicalGenius (author)  ccison1 year ago
Actually treated wood is essentially it's in a stable state and it's safe for indoor use. It would require you to continuously cut or create a form of sawdust from your treated wood in order to facilitate that sort of issue. Most treated woods are incredibly stable, and safe for indoor usage.
seamster1 year ago
Looks like a tank of a workbench! It should hold up through all kinds of abuse.

If you find those wooden clamp things getting in the way, you could fasten the top piece of hardboard with a handful of countersunk screws. Just a thought.
MusicalGenius (author)  seamster1 year ago
Thanks! That's not a bad idea for the hardboard, although since it's so thin as soon as you countersink some screws it may have passed through the hardboard.
sleeping1 year ago
Nice Instructable. Thanks for the write up. The side 2x4 may do with one or two carriage bolts into the 4x4, it seems they are held up mostly with couple of screws.
MusicalGenius (author)  sleeping1 year ago
I had thought about that, but didn't want to have carriage bolts running up against one another inside the post, I'll keep it in mind for future additions though!