How to Make Your Own Workbench

A homeowner/handyman should have his own workbench, but it may be difficult to find one exactly like the one desired. The answer to this is to draw a sketch of what you would like and go from there.

Things You'll Need

• 4 pieces of 2-by-4-inch lumber, 40 inches long
• 4 pieces of 2-by-4-inch lumber, 10 inches long
• Wood glue
• Variable-speed drill
• Phillips-head screw tip
• 2 1/2-inch deck screws
• 5 pieces of 2-by-4-inch lumber, 30 inches long
• 3/4-inch plywood, 30 inches by 60-inches
• 1 1/2-inch drywall screws
• 4 pieces of 2-by-4--inch lumber, 27 3/4 inches long
• 3/4-inch plywood, 31 1/2 inches by 61 1/2 inches
• 2 pieces 3/4-inch plywood, 6 inches by 61 1/2 inches
• Two pieces of 6-by-30-by-3/4-inch plywood

Instructions

1. Place the four pieces of 2-by-4-by-40-inch lumber (the legs) on a worktable along with the four 2-by-4-by-10-inch lumber pieces.These are the legs and the supports for the bottom shelf.

2. Apply glue to the 10 inch pieces and place them on the 40 inch pieces even with one end. Secure them with the 2 1/2 inch deck screws.

3. Apply glue to the tops of the 10 inch pieces. Place one of the 2-by-4-by-30-inch pieces of lumber between the two 40 inch pieces and let it rest on the tops of the 10 inch pieces. Secure them with the 2 1/2 inch deck screws through the 30 inch piece into the 10 inch piece, and through the 40 inch piece into the 30 inch piece.

4. Secure another 30 inch piece of lumber between the remaining 40 inch pieces as you did in Step 3. These are the legs of the work bench with the supports for the bottom shelf.

5. Apply glue to the tops of the 30 inch pieces of lumber. Place the 30-by-60-by-3/4-inch plywood on the 30 inch pieces of lumber and secure it with the 1 1/2 inch drywall screws.

6. Apply glue to one end of each of the remaining 10-inch two-by-fours, and secure them to the ends of another 30-inch two-by-four to create a support for the center of the bottom shelf. Apply glue to the top of the support, slide it under the shelf and secure it with the 1 1/2 inch drywall screws.

7. Apply glue to the 2-by-4-by-27 3/4-inch pieces of lumber and place them vertically against the 40 inch pieces (the legs) and let them rest on top of the bottom shelf. Secure them with the 2 1/2 inch deck screws.

8. Apply glue to the tops of the 27 3/4 inch pieces and secure the remaining two 30-inch two-by-fours to them with the 2 1/2 inch deck screws. Next, place the 31 1/2-by-61 1/2-by-3/4-inch plywood (the bench top) on top of the assembly so that it hangs over the edges 3/4 inch all the way around. Secure it to the 30-inch pieces with the 1 1/2-inch drywall screws.

9. Apply glue to one of the long edges of the 6-by-61 1/2-by-3/4-inch plywood pieces; place it against the 61 1/2-inch side of the workbench and push it up against the bottom of the top. Secure it to the top with the drywall screws. Repeat this with the other piece of 6-by-61 1/2-by-3/4-inch plywood on the other side of the bench. These are the front and back skirts, which support the plywood bench top.

10. Place the two pieces of 6-by-30-by-3/4-inch plywood on the workbench. These go on the ends of the bench. Apply glue to three of the edges, place them against the 30-inch side of the bench and push them up to the bottom side of the top (they also fit between the front and back skirt from the previous step). Secure them through the plywood bench top and the two 61 1/2-inch pieces (front and back skirts) with the 1 1/2-inch drywall screws.

Tips & Warnings

• Clean excess glue immediately with a damp cloth.

• If needed, countersink the screw heads on the top of the workbench.

• Do not leave power tools unattended in the presence of children.

• Do not stain or paint the work bench without proper ventilation.

References

• Popular Mechanics: How to Build a Workbench: Simple DIY Woodworking Project

Resources

• Inside Woodworking: How to Build a Workbench