How to Make Workbenches

Whether framing pictures, building furniture, tearing apart small engines or just completing everyday repair and maintenance projects around the house, you can enhance almost any work space with a well-designed workbench. If you need tool storage or a place to store hardware and supplies, consider built-in cubbies or cabinets. Whatever your demands, a custom workbench can be your most valuable tool. While you can choose from among many commercially produced workbenches, building your own workbench can save money and provide you with a truly customized work space. Choosing the correct material, adding needed features and planning for shape, size, etc. may seem difficult, but with a little preparation you can have a work surface that serves your needs, increases productivity and makes even work a pleasure.

Things You'll Need

• Drawing, measuring and layout tools
• Circular or table saw, or handsaw if you prefer
• Plywood and frame lumber to accomodate your design
• Cabinet door and drawer hardware (optional)
• Castors or wheels (optional)
• Compressor and nailgun, or hammer and nails
• Drill and screws
• Wood glue
• Paint or stain
• Paintbrush and painting supplies
• Peg board and hooks (optional)
• Power strip or surge protector (optional)

Instructions

Planning Your Bench

1. First, determine your needs. Take into account all types of work you'll commonly perform on your workbench. List materials and tools that require storage, as well as special needs you may have such as hardware or supply bins, pegboard or other specialized storage, electrical connections and lighting. Also take into consideration how much weight or abuse the table needs to endure. You may be able to perform some craft projects a table with a simple frame, while larger jobs may require heavier framing and additional support.

2. Next, take accurate measurements of the space where you'd like to use the workbench. Leave enough space to work around the bench. Measure doors and openings to ensure that the table will fit into the space. Design your bench large enough to acomodate your work but small enough so you can access the entire surface easily.

3. Now it's time to skech out your idea. Make notes on size, shape and material. Include any doors, shelves and drawers you want for tools and supplies. Try to make your plan as detailed as possible. Spending a little extra time here can save a lot of time and money in the end. You might try visiting home-center websites to get ideas from their commercially available workbench options.

4. Make a scale drawing including all dimensions. Determine size, shape, material and quantity of all pieces to be manufactured. You can do this by hand or use a three-dimensional computer drafting program such as the free Google Sketchup. Once you have your design, determine the pieces you will need to assemble each section of the bench. Write a detailed list including all dimensions and materials for the legs, top, shelf and other components.

Assembly

1. Carefully cut and measure all the pieces; cut longer and larger pieces first to make the most of your materials. Predrill holes for any screws and mark placement of hinges drawer hardware. Check pieces for proper fit, and make any necessary adjustments.

2. Break your work into sections, and as with any table or cabinet project, assemble from the ground up. Start with your leg or base structure. Build the frame as strong as possible by gluing and screwing or nailing each joint. Consider adding corner brackets to major joints such as the top corners and the corners of any lower shelves.

3. Complete as much of the frame as possible before adding large sheet pieces such as tops or doors, which will ease access to corners and other joints. Keeping each joint tight will provide years of trouble-free use.

4. You'll generally add doors, drawers and shelves last and install the top of the bench as close to the end as possible. Read any instructions that come with your hardware. Place all hinges and drawer slides carefully for optimum function. First place hinges and drawer slides with two or three screws, then test, adding remaining fasteners once you are certain you've placed them correctly. Predrilling screw holes will make installation of hardware easier.

Finishing Touches

1. Once you've completed the construction, it's time to add any finish you want. Consider what type of abuse the pieces will take. Will you be cutting directly on your worktop? If so, add a good coat of beeswax. Paint or lacquer-type finishes can become tacky or stick to sensitive work pieces; find out the properties of your finish. If you work with delicate craft projects, you might want to consider a piece of formica-type laminate for your top. For the front and sides of your bench, any type of paint or finish will work. If you work on lawnmowers in the garage, plain wood may be fine. Paint drawer fronts and doors seperately from the bench; just unscrew the hardware, paint and replace.

2. After all finishes and paint have dried, add a power strip or surge protector for easy access to electricity. Just remember to test the power supply. A lamp or two clipped or bolted to the bench can add much-needed light in just the right places.

3. Finally, install vices and any other tools that require fastening. If you need to drill or cut through your finished surface to install them, use masking tape on top of your finish to minimize chipping. Fill up all those drawers and cubbies with the tools of your trade, and get to work.

Tips & Warnings

• If you need a flexible work space, consider adding castors or wheels to your table to move it out of the way, or hinging a section to fold up when not in use.

• Always read and follow applicable safety precautions on all tools and materials.

References

• Garage Workbench
• Electronics Workbench
• Woodworkers Workbench

Resources

• Workbench Ideas, Plans, Etc.