Introduction: Timber Workbench

Welcome to the Manliest Workbench Build Ever!

Step 1: Locate Wood and Begin Cutting

A friend of mine has a dead tree removal service, so with a steady supply of potential material I decide to make a super-manly workbench. We acquired two hefty logs cut from a dead pine tree.

Using an Alaskan Chainsaw mill, we built a jig to assist with the first cut, to remove the top rounded part of the log. I wanted planks and legs for the workbench that were way bigger than anything you could get at Lowes or Home Depot.

The poor mans saw mill is adjustable, so for the second cut, we dropped the depth to 8".

Step 2: Making Legs

I wanted the legs to be approx. 8"x 8". So we rotated the log 90 degrees, re-attached the jig, and cut off the rounded part of the log. Then drop the mill setting to 8" depth and cut again.

Initial length of the legs was 48".

Step 3: Planks

Repeated these step for the planks on a second log. The log was cut with the chainsaw to be exactly 12' in length. Depth adjusted on the mill to 4". Each plank ended up being approximately 12" wide. It varied a bit from plank to plank with some natural curvature of the log. I wanted the front plank of the bench to retain the Live Edge look, but the back side of it, and both sides of the second plank were cut at 90 degrees to the surface.

I first used a belt sander on the planks to get rid of the chainsaw cut marks, but then decided I wanted a more 'rough' look so I sandblasted the top surface. The sand will blast out the softer wood and leave the grain, which is harder and more resistant to the sand.

Step 4: Back Board

I decided to make a sort of 'backsplash' that I could hang tools on, so I cut an extra plank at 2" thick x 12 ft. Came up with a better idea later and decided to install power there.

Used the router again and routed in two parallel recessions for the two power strips I bought.

The power strips required some modification because the pre-wired plug came out the end and I needed it to come out the back of the strip... But that's Another Instructable!

Step 5: Bench Top Assembly

There might have been an easier way to join the two planks, but I used a 1/2" spade bit (12" length attached to a 12" bit extension) to bore horizontally through the planks, starting from the rear. I intentionally stopped approximately 4" from the front of the front plank. Working with the planks upside down, I approximated the location of where the bore hole was, and used a router to create a 2"x2" hole. That connected to the drilled tunnel.

I unfortunately didn't take any pictures of this part of the assembly, but I used 4 pieces of 3/8" all-thread, about 18-20" in length, placing two fender washers and a nut on the all-thread in the routed hole. After drilling out matching holes in the backboard, it was placed on the all-thread and secured with two fender washers and a nut. One person can hold one of the nuts with a wrench, and the other can use a ratchet to tighten the rear nut, drawing the two planks and the backboard together. The all-thread were spaced out about every 24 inches along the length of the bench.

After assembling the work surface, it took an extra few hands to safely help me flip the work surface. Then using sawhorses and more help, assembled the legs in position for a mock-up. I decided the 48" legs were way too high, so I trimmed them down to 40" with the chainsaw.

Step 6: Final Assembly

With the bench moved back I to the garage, the legs were added with it in its final position. 2 7/8" HeadLok screws were used to affix sturdy right angle braces to two adjacent sides of each leg.

Chrome diamond plated power strips fit in pretty nice.

Also added another black pipe feature, this holds the shop towels.

Step 7: Shore It Up

You can see from this picture of the underside, there were some gaps. I don't own the precision saw equipment that can handle the size of this timber, so a chainsaw had to do. There was a little bit of a wobble and I wanted the bench to have a more Industrial look so I braced the rear legs to the underside of the bench with 2" black pipe bought down at the plumbing store. What you see are: a 12" section of pipe, connected at each end by a 45 degree ell and a floor flange.

On the front I decided to get fancy. I designed a swivel stool that hangs from the underside of the bench, and is connected to the leg at a right angle. The wooden bench seats were pre-fab you can pick up at Lowes.

Finally, added the foot rail across the front. It's set out further from the bench on the right. Due to the curve of the log, the right front leg started further back in.

Step 8: Final Touches

At the end, I still had to use a few shims to stop the wobble. Also, due to the drawn out nature of this project (8 mos) one of the bench planks warped a bit, making the work surface a little unlevel. This is my first project with non-Lowes acquired wood so there's some more learning to do. Perhaps the wood would not have warped if I would have built the entire bench immediately, or dried it in a kiln. (Read that Instructable).

Also, I treated the wood with some stuff called Bora-Care, which kills any critters in there. There were definitely some pine beetles because I found larvae several times after discovering sawdust underneath one of their bore-out holes. The worm holes add a nice touch though.

Not sure what's up next for the bench. I'm thinking about distressing it with chains, files, ball peen hammer and the like. Then distressing it with motor oil in some spots or different shades of stain... Lots of methods out there that I've been reading about.

Thanks for checking it out!

Comments

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flytraq made it!(author)2016-10-27

Outstanding build and instructional. You will need to level the bench two or three times the first year, a couple of times the second year, and then it will start to settle down. Well worth your effort no doubt. It is pure workbench porn. Beautiful. The black pipe really adds to it. I love it.

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Yonatan24 made it!(author)2016-02-24

Hi, I've added your project to the "Make Your Own Workbench!" Collection

This is the link If you are interested:

https://www.instructables.com/id/Make-Your-Own-Work...

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Carter+Hildebrandt made it!(author)2015-04-24

i want to build this so bad!!!!!!

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terrefirmax2 made it!(author)2015-03-07

I find just using it, including eating, writing on it, doing projects, including spilling stuff etc will distress it just fine. And then you have all those memories. (esp if you let kids have access!)

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dsantil71 made it!(author)2015-02-02

That is gorgeous. The warping could also be contributed to where u placed the legs & how big it is. Popularwoodworking.com has a lot of free pfd files that u can download once u sign up as a free member. There's one I really like that called "How To Build A Table". It's 14 pages of info! I love how you added the pipes & installed the seats. Freaking awesome!!

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Porda made it!(author)2015-02-01

Now that's a man's work bench.

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DOT. made it!(author)2015-01-31

Wow! This workbench is truly amazing. I like how those pipes and wood combine together. By the way, thumbs up for that old school chopper. What is its model?

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PikesPeakHHO made it!(author)2015-01-29

Beautiful bench - awesome! I really like how massive and sturdy it is. Great work!

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john.ostermann made it!(author)2015-01-19

Thanks all... THIS is on the other side of the garage... :)

15, 4:23 PM.jpg
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slickslam made it!(author)2015-01-23

Do you have a link to an instructable for that?

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john.ostermann made it!(author)2015-01-23

Not yet but I'd like to put one up... Stay tuned.

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xxlauraxx made it!(author)2015-01-29

+1 for an 'ible for that. :)

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ElectroFrank made it!(author)2015-01-28

With greatest respect to your most excellent build, I am astonished by your mention of "distressing" ! Why would you work so hard at pretending to be busy ? You made a workbench, not a fashion accessory !

Get more constructive, not destructive, just use it ! Strip a few engines, weld a chassis, build a boat ! The bench will then gladly join with your creations in bearing witness to your skill and creativity !

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CaptMike001 made it!(author)2015-01-27

I was wondering if you chose to make it out of pine by fluke, i.e. It was available, or because of its light wt. and easy workability.

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john.ostermann made it!(author)2015-01-27

Probably both. We've got a ton of it around, and was easy (relatively easy) to cut. A hardwood like oak, which we also have, would have been a monster pain to cut. As it was, each horizontal cut down the length of that pine still took about 15-20 minutes of pushing and jimmying the chainsaw. We would also stop and add shims to the cut so the newly forming plank didn't bend back toward the log and potentially bind the saw.

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tmueller6 made it!(author)2015-01-27

Dude, this is bad ass! I agree that allowing the wood to dry would have made this a much easier build. Regardless, this table is gonna have some character and be a total heirloom. Kudos!

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john.ostermann made it!(author)2015-01-27

too kind, thx!

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ThisFlynn made it!(author)2015-01-27

When milling your own lumber, make sure to at least let it dry.
This could account for a lot (if not all) of your wobbling.
Here's a great instructable on building your own kiln.

I'm definitely asking for a Chainsaw Mill for my birthday!

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john.ostermann made it!(author)2015-01-27

I think this is the intractable i mentioned in mine... agreed.

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zaphod07 made it!(author)2015-01-25

nice job man, that would make a real nice reloading bench.

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john.ostermann made it!(author)2015-01-27

thank you!

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Ferk%C3%B3K made it!(author)2015-01-27

Wow, brilliant! Well done, mate!

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john.ostermann made it!(author)2015-01-27

Thank you

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WyldStyl3 made it!(author)2015-01-27

This is freaking awesome!

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john.ostermann made it!(author)2015-01-27

thanks

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olanderd made it!(author)2015-01-27

This is the best workbench project I have seen to date. Very creative. Well done!

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john.ostermann made it!(author)2015-01-27

Thank you!

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tjk1939 made it!(author)2015-01-27

Like the bench. The scooter looks good also.

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john.ostermann made it!(author)2015-01-27

Ha! Thanks, and thanks!

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jtharkness made it!(author)2015-01-27

Awesome. Love the idea and the execution.

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john.ostermann made it!(author)2015-01-27

Thanks!

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DR_UNIX made it!(author)2015-01-27

Do you have an Instructable for making the swing out stools?

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john.ostermann made it!(author)2015-01-27

It's on my list...Hopefully coming soon

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davidandora made it!(author)2015-01-27

Beautiful bench and a great instructable. The black pipe additions look great. I especially like the stools with foot rail. Smart looking functionality!

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john.ostermann made it!(author)2015-01-27

Thank you!

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bigburcie made it!(author)2015-01-19

Depending on how much warping there is, you could probably smooth it out with a nice big hand plane (manual or powered) or if you want it super precise, there is a method I've seen using a router set up in a sliding box on rails making passes back and forth to knock down the high spots. Marc at Woodwhisperer.com has a video on how he did his.

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john.ostermann made it!(author)2015-01-23

I'm thinking about making some kerf cuts underneath, and keeping the plank wet with a big towel... using weights or ratcheting straps to draw it down over time?

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tytower made it!(author)2015-01-20

Needs a vice dude

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john.ostermann made it!(author)2015-01-23

You're right, and I have the jr. Size one from my last workbench but it didn't seem right here... Need to find a huge one for this bench.

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grumpybarista made it!(author)2015-01-23

Very cool looking bench! I wonder about the strength of the seating. How is that working out? Seems like a person might bend the seat arm, and possible also strain the fixture at the leg. And feedback on that?

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john.ostermann made it!(author)2015-01-23

That's 2" pipe. I'm 220lbs and it swivels fine. Maybe someone else will chime in but I'd estimate it would take 500lbs or more to come close to bending it.

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Dustin+Rogers made it!(author)2015-01-23

Looks great man. Check out a finishing technique called shou sugi ban. It's basically charring the wood with fire (which burns out the softer wood first), cleaning it via wire brush to remove some of the charring, and then applying an oil finish. There's a couple youtube videos showing the process and results.

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john.ostermann made it!(author)2015-01-23

I like that, will check it out

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adamwatters made it!(author)2015-01-22

Hardcore.

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3366carlos made it!(author)2015-01-21

super awesome man!

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vicnur made it!(author)2015-01-19

very good condition!

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mgrunwel made it!(author)2015-01-19

This would be an awesome set up for a bar in a cramped space.

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tcristian made it!(author)2015-01-19

you rock :)

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tlp801 made it!(author)2015-01-19

What, no beer tap or john..? Maybe in the 2.0 version. Ha! I give it 5 stars, it's pretty awesome!

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maKACS made it!(author)2015-01-19

Heavy duty. :) Cool!

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