DIY Portable Workbench (knock-down Design) With a Leg Vise and Storage - From Scraps and Simple Tools!

In this Instructable I show how to build a woodworking workbench that can be disassembled for transport.

this workbench is built entirely from scrap wood, using mostly hand tools. it's relatively small (1m wide), so it fits easily into any car.

I've used this workbench for more than 5 years and it is very comfortable and also extremely sturdy, thanks to the storage space which is packed with tools.

the design is based on the this article, especially the notched stretchers.

some notes:

- I used mostly hand tools to build this workbench. it was a personal choice to show that you don't need fancy woodworking tools to build a good workbench.

- the storage area is optional. personally, I added it a few months after the workbench was complete

- the leg vise is my own design, inspired by the moxon vise.

- the video shows how I assemble the workbench after transporting to my new apartment.

I hope this article helps you with designing and building your own workbench.

Supplies

scrap wood (2x4's, old door frames etc.)

woodworking tools (saw, drill, rasps, planer etc.). I used mostly hand tools because it's fun!

Optional - for the leg vise:

threaded rod with 2 bolts and a washer - diameter 20mm or more, rod length around 40cm

square metal or wood bar

Optional (for drawers) - drawer rails and material

Step 1: Build the Top Surface

I built the top surface from scrap door frames I found on the curb.

I recommended using 2x4's, but as you can see it can be done with any scrap wood - as long as it doesn't contain metal, screws, nails etc.

first, I use a hairdryer to remove the vinyl wrap, revealing laminated wood and glue.

I scraped off the laminate and glue with an old woodworking plane.

then, I planed the glue up surfaces with a no. 4 plane.

to make glue up easier, I drill holes and insert dowels that keep mating surfaces aligned and prevents them from sliding.

I don't have any large clamps, so I improvised with a couple of leftover planks and wedges. wedges provide excellent clamping force!

I also found a small table top that was almost the exact dimensions. I glued it below the work surface to add extra height and strength.

Step 2: Make the Legs

The base shape of the legs is a large "A" (or "R"). it is relatively easy to build from straight pieces.

I'm using hand tools, including a hand saw and chisels, so I recommend creating "knife walls" for cleaner saw lines and guiding the saw,

I improves a shooting board for 2x4's using a wedge, and used it to clean the edges.

Tip: when creating 2 or more identical pieces, I recommend marking and copying elements from one piece to another (instead of measuring). in my case - I copied the locations of notches for the stretchers from one leg to another.

I prepared all the stock material, and then I glued and screwed everything together.

Make sure to check that edges are straight and square.

Step 3: Build the Stretchers

The stretchers provide rigidity, they prevent the frame from racking and the bench from rocking. They are meant for easy disassembly.

as mentioned before, stretcher design is based on this article at woodcraft.com.

in principle, a single bolt creates 2 focus/pressure points against the leg.

in order to secure the bolt, a hole is drilled into the stretcher for the nut.

if you plan on adding a storage shelf, make sure that the stretcher tops are level with each other.

Step 4: Assemble the Top to the Base

connect the top to the legs using bolts similar to the stretchers. I use 4 bolts - 2 on each side.

make sure to sink the bolt heads well below the top surface!

after everything is connected, check for level, plane the top and optionally apply finish (in my case, boiled linseed oil).

Step 5: Build the Leg Vise (moxon Style)

this leg vise is based on the Moxon style bench vise, check the video to see how it works, and see the assembly video above for a breakdown of the parts.

it uses simple materials:

- 20mm threaded rod,

- 2 nuts

- metal square tube

- some wood and bolts.

The vise is relatively easy to make (see pictures):

- drill the top hole in the leg for the threaded rod

- drill the bottom hole for the tube, and square it using a chisel

- attach the square tube to the leg vise.

- fix one nut to the back of the leg

- fix the other nut to the wheel

and that's it!