almost no tools. Everything but assembly is done for you at homedepot or lowes with the exception cutting the notches for the lower shelf. The assembly is pretty modular so it can also be modified to fit longer table tops, or change the leg lengths and height. The only negative aspect of building a workbench this way is that the components are fairly expensive. Total cost for the project is around $200.
Step 1: Materials
8 pieces of 6" long 1 1/4" pipe
4 pieces of 24" long 1 1/4" pipe
1 piece of 36" long 1 1/4" pipe
8 flange connectors
1 sheet of 3/4" plywood cut twice:
- cut 2' from the length to make a 2'x4' piece and a 4'x6' piece
- cut the remainder lengthwise to make 2 2'x6' pieces
* saw & screw gun recommended
I chose to use 1 1/4" black gas pipe to make it heavy duty without being total overkill. It would have been much cheaper & quicker to go with 1" pipe since more of the parts are available pre-cut. Either way you'll need to buy more pipe than you really need from their 10' pipes: 10 = 4 legs & 2' scrap or 3 legs, 1 center part, & 1' of scrap. Maybe you'll get lucky & find the extra foot or so in their cutoff bin.The main table top really only requires 1 piece of 2'x6' plywood, but doubling that up makes it much sturdier and the scrap from that sheet can be made into a lower shelf.
Step 2: Assembly
1. A T-connector goes on each end of the 3' pipe.
2. Each of those gets a 6" pipe for the lower leg and a 24" pipe for the upper portion.
3. A flange connector finishes off each end of the legs.
4. Put the 2 6'x2' plywood sheets on top of one another with the side you want exposed facing down.
5. Flip the pipe assembly onto the table top so that the short leg sections now point up.
6. Position all the flanges so that they are spaced a couple inches from the front & rear edges.
7. Screw the flange connectors to the table top with 1 1/2" screws. If you do this step first without assembling the pipe structure, you won't be able to put it together correctly.
8. Flip the table back onto its feet & either adjust the leg lengths by tightening / loosening them or putting shims under the wobbly foot.
9. Mark & notch the corners of the scrap plywood to fit on the lower pipe brackets.