Introduction: Heavy Duty Workbench
Every guy or girl should have an all purpose work bench! This is a very simple, very strong and inexpensive one you can make in an afternoon! This workbench will last a lifetime! Now I am no carpenter and there may be a better way to build this project but this is what works for me! I built this for around $100.
First, lets talk tools= Tape measure, chop saw, speed square, carpenters pencil, drill, Jig saw with wood cutting blade, hammer, power screw gun.
What materials you will need for this project.=
5 12' 2x6" boards
1 8' 2x6" board
2 8' 1x6" boards
Wood glue, 3" deck screws, 2" screws for bottom boards
Step 1: Start Out Cutting for the Top of Bench.
1. The top of the workbench will be 6' wide and 28" deep. You will start out with 3 12' long boards.
2. Place 12' board up on the saw table....be sure to support the other end so that it sits flat on the table.
3. Using your tape measure, measure out 6' and mark it, then used your speed square to mark the line.
4. Before cutting, be sure to have the blade on the outside of the 6' line.....if you cut on the line your measurement will be off because of the width of the blade. This is also why you shouldn't mark several cuts before cutting on one board.
5. Make your cut, the 12' board should be a bit over 12'.....after the cut, measure out another 6' and you should need to shave a bit off the end. Repeat this step until you have 6 6' boards for the top. Set them to the side.
Step 2: Cutting the 4 Side Rails, Top Front and Rear Boards
1.You will use 1 12' 2x6" for the 4 side rails.
2. Measure out 28" and draw cut line using your speed square.
3. Cut on the outside of the line as before.
4. Repeat this step until you have 4 28" 2x6" boards. There will be a bit left over after this step.
5. Time to cut the top front and back rails, these will connect the sides of the bench.
6. Use one 8' 2x6" board and measure out 43 1/2" , make the line with the speed square, cut on the outside of the line...repeat this step. You will now have the top front or "face board" and the rear...these will connect the sides.
Step 3: Cutting Legs for Side Rails.
1. For the legs we will use 1 12' 2x6" board.
2. Measure 33 1/2" and draw line with speed square. Cut on the outside of the line.
3. Repeat this step until you have 4 boards for the legs...there will be just a bit of scrap left.
Step 4: Notching Out the Legs.
Time to make the notches for the side rails, this will make the bench super strong.
1. Using the leftover scrap section, place it on the top of the leg, outer top corner and trace it onto the leg. (see photo)
2. On the bottom of the leg, opposite side, measure up 5 1/2" and mark...place the scrap piece end on that along the side and trace again.(see photo) Repeat these steps on all 4 legs.
3. Time to cut out the notch.....first drill a hole large enough for the jig saw blade to fit into. Then using the jig saw cut out the notch...be sure to cut inside the lines for a tight fit! You will not need to drill a hole for the top notch. Repeat for all 4 legs.
4. Test fit the side rails!
Step 5: Assemble Sides of the Workbench.
1. lay down 2 of the legs, apply a good bit of wood glue to the inside of the bottom notches.
2. Install the side rail, if the fit is very tight use a hammer to get it in the notch....do not hammer directly onto the side rail, use a scrap piece to lay over the top. (see photo)
3. Drill a few small pilot holes into the end of the side rail. (this will keep the wood from splitting)
4. Install deck screws, 2 per each end.
5. Repeat for the top and other side....clean off excess glue with a wet rag.
You now have the sides of the workbench!
Step 6: Installing the Top Rails!
1. Lay the end on it's side......the top rails will go on the inside of the ends. (see photo)
2. Glue the inside top, place the top rail tight against the inside edge.
3. Drill pilot holes and then screw into place with 2 screws. (see photo)
4. Repeat on the other side and then flip base over to install the other top rail.
You will now have the "base" of the workbench.
Step 7: Head Board and Top Install
This will be the "head board". It will help protect the wall behind the bench and you can also mount a power strip to this.
1. Lay one of the 6' boards flat and then stand one on it's side on top of it. Line it up with the outer edge of the flat board and trace a line. (see Photo)
2. Now that you know the width of the board measure and mark at every 12" from the end. Drill a pilot hole in the center of each mark. I also measured in 2 inches on each end and drilled another pilot hole.
3. Lay the top board down flat, bring the board with the holes in it right up against it forming an L shape and screw together
4. This will now be the head board for the bench. Lay down some wood glue to the top of the base. Place the head board on top of the glue and center it. The base will be just under 4' wide so the top boards will hang over each side...will be just over a foot on each side.
5. Drill a pilot hole on each side of the head board where it sits over the base and screw into place.
6. Repeat with each board.....glue on top of that base, place board flat on top of the base. I install 2 screws on each end of the remaining top boards. I also leave a very small gap between the boards for easy cleaning.
Step 8: Cut and Install Bottom Shelf.
I'll bet you were wondering when we were going to use the 2 8' 1x6" boards?? Well this is it!
1. Cut the 8' boards down to 42 1/2"....this will give you 4 of them.
2. You can choose to just cut the bottom shelf boards in half and the shelf will be a bit wider with a larger overhang.
3. Center the boards on the base, space them out evenly with a small space in between the boards. Drill pilot holes and with the smaller screws attach to the side rails,,,you now have a bottom shelf.
I also installed a bottle opener and an aluminum yard stick...makes a quick measurement easy and you can use it as a straight edge! Now use that new bottle opener to crack open a cold one, sit back, breathe in that fresh wood smell and gaze at your new workbench!! Hope you still have all of your fingers and toes!