Introduction: DIY Small/Portable/Convenient Workbench
In this instructable / video I am going to show you how I made this small, portable, capable and very convenient workbench with integrated jigsaw (+ blade guide) and a vacuum (+ dust collection system), that you can actually use at home for small scale woodworking projects.
As I never done woodworking project of scale like this, I took some time to do full research and sketch my own workbench. My goal was to create something small, portable, convenient, as much as possible dust free and low noise. To be honest, I am really glad how this workbench turned out. It is day and night compared how I worked before! :D
Accessories for this workbench: https://www.instructables.com/id/Accessories-for-...
Router integration and more accessories: https://www.instructables.com/id/Router-Table-Jig...
If you want to make one yourself here is the free plans of the workbench: http://bit.ly/SPCWorkbench
Provided Amazon links are affiliates
Tools You'll Need:
- Drill: https://amzn.to/2U5QQmL
- Jigsaw https://amzn.to/2rg4uXx
- Jigsaw blade for straight cuts https://amzn.to/2E8TgfY
- Router https://amzn.to/2DVXXZC
- Shop vacuum https://amzn.to/2umMjkQ
- Circular saw https://amzn.to/2PaxiKx (optional)
- Straight guide https://amzn.to/2E53wWg
- Speed Square https://amzn.to/2Qat9vz
- Clamps https://amzn.to/2E8EBkQ
- Tape measure https://amzn.to/2rfS4Ph
Materials You'll Need:
- 18 meters of 28x70 mm wood boards (local hardware store)
- 18 mm thickness 85x56 cm (final size) plywood sheet (local hardware store)
- 18 mm thickness 70x46 cm (final size) plywood sheet (local hardware store)
- Power socket (local hardware store)
- DIY electronics component box https://amzn.to/2KV4SXz
- Locking casters https://amzn.to/2uwHYdV
- ON / OFF button box / power switch https://amzn.to/2KMN1yL (works without additional relay)
- Bearings 607ZZ 7x19x6 https://amzn.to/2JluuHv
- Bolts 2x M6x70 for the adjustable blade guide (local hardware store)
- Bolts 8x M6x50 for the jigsaw clamping and for other blade guide parts (local hardware store)
- Washers M6 (local hardware store)
- Clamping knobs 32mm M6 https://amzn.to/2zBBFcp
- Wing nuts M6 https://amzn.to/2U6lufK
- Threaded e-nut M6 https://amzn.to/2rhZCB4
- Wood screws 24x 6x70mm for the frame (local hardware store)
- Wood screws 14x 5x60mm for the top and bottom plywood (local hardware store)
- Wood screws 2x 5x50mm for the extension board (local hardware store)
- Wood screws 16x 5x30mm for the casters (local hardware store)
- Wood screws 2x 4x20mm for the button box (local hardware store)
- Drainage / sewage elbow (local hardware store)
- Wood glue: https://amzn.to/2E8Baus
- Sandpaper https://amzn.to/2zHDiaY
- Hard polyurethane varnish https://amzn.to/2zCnt30
- Styrofoam board (local hardware store) (optional)
- Old inner tube of bike’s tire (optional)
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Step 1: [EXTRA] Jigsaw Table Accessories
After this, don't forget to watch how I made accessories for this workbench (crosscut sled, rip fence, downdraft box)!
These accessories makes this workbench extremely handy station for small scale woodworking projects!
Step 2: Preview
Step 3: Cutting Wood Boards
I bought 18 meters of 28x70 mm wood boards. At hardware store, I done rough cuts and then in my garage, done clean accurate cuts.
I done almost all cuts with a circular saw to save time. But this build can be done entirely with a jigsaw. You just need to use blade which doesn't bend so much and is designed to get straight cuts.
Step 4: Gluing Legs
I made one workbench leg from two glued boards of 84 cm. This will make leg super strong and straighter, as wood boards are usually slightly curved.
Step 5: Front Frame Assembling
I squared all corners, drilled pilot holes, countersunk them, slightly threaded screws that they stick out just a little bit, added wood glue and tightened screws. By threading screws just slightly, later it is very easy to place the board in the exact same spot.
I made that the top wood part would face inside. This will give more clamping space around front of the workbench.
Step 6: Back Frame Assembling
Using same method as before, I finished back frame of the workbench.
Step 7: Everything in Place
I placed all parts of the workbench where those supposed to be and added some weights to hold them in place. I assemble first one side, then other.
Like before, I squared all corners, drilled pilot holes, countersunk them, added wood glue and tightened screws.
Step 8: Finishing Frame
I placed weights around the frame to prevent wood warping while glue are drying.
Then finished frame, by gluing and screwing top middle wood board.
Step 9: Cutting Top and Bottom for the Workbench
I cut top and bottom parts for the workbench from 18 mm plywood and then marked where the frame will be placed.
Step 10: Making Benchtop
Now I can drill holes which will hold bench-top to the frame exactly where I want. Make sure to place sacrificial wood board beneath plywood to prevent chipping.
Next, I drilled hole for the jigsaw blade.
Step 11: Placing Jigsaw
I squared jigsaw base plate to the front of the workbench and routed slot for it. Jigsaw should slide in into the spot nice and smooth.
Step 12: Jigsaw Clamping Screws
I drilled and countersunk 4 holes for the screws, which will hold the jigsaw.
Step 13: Jigsaw Clamping
To hold jigsaw firmly in place, I cut small pieces, which must be at an angle. To get this, I slightly routed around the bolts, that the nuts sit halfway into a plywood. You can use wing nuts or star shaped knobs to tighten a jigsaw.
Step 14: Dust Collection
From same 18 mm plywood, I made dust collection system. I drilled 44 mm hole into the plywood square, that drainage (sewer) elbow would fit perfectly, as it has inner diameter as my shop vac's universal connector.
Step 15: Gluing Dust Collection System
I glued that the drainage elbow would be as close as possible to the blade of the jigsaw. I supported drainage elbow's frame by gluing small triangles.
Step 16: Blade Guide
To make the blade guide removable, I drilled holes into the bottom 10 cm part. Using e-nuts, I made that screws stick out from that part. Then I drilled holes into the workbench, placed and secured that part with wing nuts.
Then I glued other two 10 cm parts on top. I drilled holes into 3 cm part and glued it to 28 cm part.
Step 17: Adjustable Blade Guide
I marked where the bearings will be, drilled holes and assembled to check if everything is good.
Step 18: Adjustable Blade Guide
I routed slots into the part that by using 2 screws, I could control height of the guide for smaller blades.
Finally, I glued 28 cm part to the three stacked blocks.
Step 19: Bottom of the Workbench
I placed workbenches' frame onto the plywood sheet, marked where the frame is and cut it accordingly.
Step 20: Finishing Bottom of the Workbench
Then I placed workbench frame into previously cut plywood part, laid down parts on side, drilled pilot holes, countersunk them and drilled 5 screws.
Step 21: Casters
I rough sanded the bottom legs, drilled pilot holes and screwed in casters. I used all four rotating and locking casters.
Step 22: Making Jigsaw Power Control
I cut extension board for the jigsaw button box / power control box. Then drilled hole for the wires from the box and screwed everything in place.
Step 23: Don't Cheap Out on Button Box
As I bought cheap button box, it was without magnetic switches. That means that I need to press and hold button for jigsaw to work. So I just improvised by using relay to make buttons work as they should. I won't go in detail about it, because you should just buy proper button box and avoid this extra work. :)
I placed the relay in DIY electronics component box where I also placed power socket.
Step 24: How This Should Work
- I plug in the jigsaw into the build in power socket.
- Then I plug in power cable (from the button box) to the shop vac (shop vac must have function to turn on when you turn on a tool)
- I press ON button, jigsaw and vacuum turns ON.
It maybe sounds complicated, but it isn't and this makes using the jigsaw much more convenient.
Step 25: Finishing Touches
I slightly sanded bench-top with 220 grit sandpaper, added hard varnish, secured wires and cables.
I additionally glued (with double sided tape) some old inner tube from bike's tire, to absorb vibrations from the bench-top.
Step 26: Final Step
Finally, I screwed bench-top to the frame.
Step 27: END
And that's it - the build is finished!
I hope this instructable / video was useful and informative. If you liked it, you can support me by liking this Instructable / YouTube video and subscribing for more future content. That means a lot! Feel free to leave any questions about this build. Thank you, for reading / watching! Till next time! :)
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