How to build a DIY workbench

Building a sturdy and functional workbench is a project that can transform your workspace, making it more efficient and tidy. Whether you are a DIY enthusiast or a skilled craftsman, a custom workbench provides the stability and space you need to tackle your projects with greater precision and organization.

This detailed guide will take you step by step through the construction of your workbench, from preparing the materials to final assembly. By following these instructions, you will have a solid, well-designed workbench that can be customized to your needs.

• Construction time: 3 hours
• Total cost: Around €240
• Skill level required: beginner – intermediate

Recommended tools for the project

• Saw (preferably a miter saw for precision cutting)
• Drill
• Impact Wrench with Screw Bit
• Sander
• Ratchet straps
• Wood Countersink Drill Bit

List of cuts and materials

To build the workbench you will need:

• (22) 50mm x 100mm x 2.4m wooden planks
• (1) 100mm x 100mm x 2.4m piece of wood
• (2) 122cm x 244cm plywood panels (preferably at least 19mm thick. The panels will form the table top and the lower shelf, so it is advisable to choose quality plywood with at least one well-finished side).

Detail of the cuts

• (12) pieces of wood 50mm x 100mm x 96.5cm
• (8) pieces of wood 50mm x 100mm x 104cm
• (12) pieces of wood 50mm x 100mm x 226cm
• (4) 100mm x 100mm x 61cm pieces of wood

Additional materials

• Approx. 2.5 – 3.5 kg of 90 mm screws (T25 star screws recommended)
• Wood glue
• Sandpaper
• 10 cm swivel wheels (other sized wheels can also be used, as long as they can be fixed to the 100x100 mm wooden uprights)
• Sixteen 15cm screws (see step 6 for more details)

With these tools and materials, you will be ready to begin your project of building a sturdy and durable workbench.

Build your workbench in 6 easy steps

Step 1: Cutting the materials

Start by cutting the wooden planks to the following dimensions:

1. (12) pieces of wood 50mm x 100mm x 96.5cm
2. (8) pieces of wood 50mm x 100mm x 104cm
3. (12) pieces of wood 50mm x 100mm x 226cm
4. (4) 100mm x 100mm x 61cm pieces of wood

Cutting the plywood panel

From the plywood sheets, take A of the two panels and make indentations at the corners of 10cm x 10cm (see diagram). This will be needed to fit the panel onto the 100mm x 100mm wooden studs.
The second plywood panel does not need to be cut, as it will be used as the bottom shelf of the workbench.

Now that you have all the pieces cut, you are ready for the next step, which involves assembling the base of the workbench.

Step 2 (DIY Workbench)

Next, take six of the 38” (2×4) pieces of wood and two of the 90” (2×4) pieces of wood and arrange them as shown in the following image (1st image). Drill holes to prevent splitting of the wood, add some glue and insert the screws. Make sure to use enough glue to make the joints solid, but do not overdo it or it may leak. Excess glue does not dye well and can affect the final appearance if not cleaned immediately with a damp cloth.

Next, add two 42” (2×4) pieces of lumber and two 88” (2×4) pieces of lumber to the ends of the frame. Add glue to all areas that will come into contact. Drill holes and insert screws.

Repeat this step to get a second identical frame. In the end, you should have two identical frames.

At this stage, we are building the main frame of the workbench, using pre-cut pieces of wood to form a sturdy and stable structure.

Step 3: Assembling the frame and attaching the legs for the workbench

• Cut the spacers: Start by cutting eight 2-inch-high spacers. You can use any scrap wood for these spacers.
• Place the spacers: Arrange the spacers and four 10cm x 10cm x 61cm (4×4) pieces of wood as shown in the picture.
• Place the frame: Place the frame assembled in the previous step on the spacers, thus raising it 5 cm from the ground. Move the 10 cm x 10 cm pieces of wood into the grooves created in the frame and glue them in place.
• Use ratchet straps: Take a ratchet strap and wrap it around the entire frame as shown. If one strap is too short, you can pair it with another to go around the entire frame. Tighten the strap to ensure that the 4" x 4" pieces and the frame do not move. If necessary, use a hammer to align any parts that do not fit together perfectly, making sure the frame and legs are flush and level (use a flat surface).
• Insert the 9cm screws: Next, drive the 9cm screws diagonally as shown in the picture. It is important to pre-drill the holes to avoid splitting the wood.
• Flip and repeat: With the help of someone, flip the frame and legs over to the other side and add more screws in the same way. When flipping, be careful not to put too much pressure on the legs, as they are not fully secured yet.

Step 4: Attaching the worktop to the frame

After completing the frame and legs assembly, the next step is to add the 4ft x 8ft (122cm x 244cm) plywood with notched corners to the newly assembled frame. Follow these instructions:

1. Applying the glue: Apply a generous amount of wood glue to all contact surfaces between the frame and the plywood. Make sure the glue covers all areas evenly to ensure good adhesion.
2. Pre-drill and fix the screws: To prevent the wood from splitting, pre-drill holes in the areas where you will insert the screws. Then, insert the screws to secure the plywood panel firmly to the frame.

Step 5: Adding the second frame and securing the worktop

In the fifth step of the project, flip the workbench over and add the second 2×4 frame assembled in the previous steps. Apply glue to the contact areas and place the 100×100mm (4×4) pieces of wood into the recessed areas of the frame, ensuring the workbench is on a level surface. Use straps to hold everything in place, tapping with a hammer to even out any irregularities.

As in the previous step, pre-drill the holes and add screws to secure the frame, both at the top and bottom. Next, secure the bench top with a sheet of plywood (122×244 cm). In this case, it is not recommended to use glue, as the top may need to be replaced in the future due to wear. Use screws to secure the top to the frame, thus maintaining the possibility of easily replacing it when necessary.

Step 6: Installing the wheels and final sanding of the workbench

Turn the workbench upside down to install the wheels. Place a wheel in the correct position on each of the four 4×4 wooden legs and mark the holes to drill. Pre-drill the holes to prevent splitting of the wood and to ensure a secure connection with the screws.

Screw the wheels onto each leg and once they are in place, sand the entire surface of the bench. Start with 80 grit sandpaper to remove the larger imperfections and continue with 220 grit to obtain a smooth surface, ready to be painted or stained.

Conclusion

Now that you’ve completed all the steps to assemble your workbench, you have a solid, functional surface ready for your future projects. The wheels will allow you to easily move it around as needed, while a final sanding ensures that the bench is smooth and ready to be painted or stained to your liking. This project not only provides you with a sturdy workspace, but also adds an element of personal satisfaction from having built it with your own hands. Happy crafting!

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