Flatpack Workbench




I'm a student at HOWEST in Belgium. I study industrial product design and for one of our projects we had to make a flat pack product. We could choose any product. I picked a workbench.

In the following steps I will explain how I made it.

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Step 1: Tools

- Drill

- Multytool or jigsaw

- Circular saw

- Ruler, pencils, ... etc.

- Knife

- cable cutter

Step 2: Materials

- multiplex: 1220x1220x18 mm

- multiplex: 1220x1220x12 mm

- aluminium tubes: diametric 40 mm and length 900 mm

- wheels

- steal cable with clips: diametric 3 mm, 10 meters long

- foam (yoga mat)

- steal bar: 400x40x5 mm

- steal tube: diametric 48 mm and 25 mm

- hinges

- screws

- wood glue

- varnish and paint (if you want too)

Step 3: Worksheet

- Fist cut the wood in 3 different sizes.

1) dimensions 80x948x12 mm (2 times)

2) dimensions 80x1200x12 mm (2 times)

3) dimensions 900x1200x18 mm

- glue en screw the side on the main plate like in the picture

- that's all for the worksheet

Step 4: Cable and Bar Holders

Steal holders:
- cut the steal bar down until we've got 6 piece with dimensions 60x40x5 mm

- cut 4 piece from the steal tube with diameter 48 with 5 mm thickness. Do the same with the small tube but only 2 times

- weld the tubes on the little plates like in the picture

Wooden holders:

- cut down 4 squares with a length of 80 mm and 12 mm thick

- drill a hole in the center with diameter 40 mm

Step 5: Bottom Plate

- first cut a plate with dimensions 1195x895x12 mm

- on this plate you cut out a U-shape with 600x895 mm and the thickness of the U-shape is 100 mm (multitool)

- place the steal cable/tube holder in the centerline of the U-Shape and screw them down

- reattach the 2 plates with hinges like in the picture

Step 6: Tool Holder

- cut the yoga mats with a knife in several pieces from the same size (you can chose your own dimensions)

- glue the pieces together

- cut the shape of the tools you want into the foam

- test if your tools fits

Step 7: Assembly

- Screw on the tube holders on the bottom plate, 190 mm from the end of the U-shape

- Screw also the tube holders on the back of the worksheet

- On the side where we will screw the bottom plate on the worksheet, we screw the cable holder on the outside of the worksheet. In the center. On the other side we screw them on the inside

- you can test if it closes

- if it closes, you can glue the tool holder on the bottom plate

- if you want to you can paint or varnish the workbench

Step 8: The Cables

- put the aluminium tube into there holders

- cut down the steal cables to the right size (no exact dimensions)

- adjust them until the worksheet is leveled

Step 9: Extra's

- put wheels on the side where the bottom plate and the worksheet are connected

- put a hole into the center of the long side of the U-shape

- put a hole on the side of the worksheet on the other side of the wheels (not necessary)

Step 10: Result

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    16 Discussions


    3 years ago

    Is it stable enough for heavy tools or leaning on it? As I see it has base which is 2 times shorter then its top.


    3 years ago

    a diagram or CAD rendering would be greatly appreciated


    3 years ago

    This is wonderful and inspiring. Please let us see how you did it. I am semi disabled so need the tools on the topp. I guess it is possible to make it with bottom part for the bass and an opening top for work furface and tool stank vertical !? What do you think. I have limited mobility and tools!


    3 years ago

    I will make some extra pictures and I will make a video how to fold and open the workbench. But at the moment I'm really busy with other projects for school so it will take some time when I'll post it.

    And thanks for all the great comments!


    3 years ago

    Great job. A project that helps a lot who doesn't have enough space or needs a portable work bench. Thanks for this project, it will be very useful to me.


    3 years ago

    Wath a great idea, everyone can come up with improvements once they see your concept, but your original idea is great and like lots of people I will be making this for myself and adding little tweets of my own. Once again great project thanks for posting.


    3 years ago

    As others have requested, a sketch or video or animation would really be nice to understand how the flatpack "packs" flat (sorry for the pun, couldn't resist)


    3 years ago

    I see the box and ply legs folds out like a Z shape with the aluminum poles setting the height and the wires strengthen and stabilises it (you could use a pull down or ratchet straps using store bought eyelets to make it easier to construct too) I could envision folding pole legs too with a little thought

    Like the tool rack on the inside to hold your gear/stuff and ubiquitous screwdrivers could max that out too

    I know once you start you always see improvements hahahaha


    3 years ago

    This is excellent! I always love projects for small living spaces. As I was reading I was having the same thought as Vettel ... Could u show a video of how it opens and closes?


    3 years ago

    cool, but an animation or drawing of how it folds is missing. Or video!?

    Its hard to guess see from closeup pictures..


    3 years ago

    Multiplex is called plywood in the UK. There are many grades from rough to Lloyds Register approved. The roughest grade is used or shuttering concrete; Far Eastern, or WBP has a nice finish; birch ply is very strong and used for finished products, but costs a fortune; Marine ply is off-limits cost-wise.

    B&D used to use birch ply, but now use what looks like bamboo flooring planks - still hugely strong. Any of the "laminate" flooring boards are often a cheaper source of stable planks.

    Instead of welding up rings on plates, why not use the ready made versions? Called "ring on a plate" or "hook on a plate" from ironmongers or really posh ones from a chandlers shop in stainless steel.

    "cleats" could be useful and "turnbuckles" are purpose made to tighten steel wire.


    3 years ago

    ok crazy question what is a flatpack work bench? Not trying to be a smart alick. When I saw the photo thought it was a lift table.

    1 reply

    Reply 3 years ago

    Loads of examples, from Black and Decker Workmate to wallpaper pasting table - picnic table, cards table? The B&D might be a bit bulky to be considered flatpack, but I have two of the originals over 40-years old and totally tight and rigid owing to really good design.


    3 years ago

    Very nice! One question. Can you add some photos or description showing how the steel tubes are installed and how they are stored.


    3 years ago

    I think I need to make this and use it for a portable close up table for when Im performing magic while busking!


    3 years ago

    Very cool! I think this is one of my favorite flat pack projects.