Woodworking Articles & Tips

How to Build a Work Bench - Easy Guide

By Dave Richard

Building this work bench over the weekend is a snap and it will serve you well for a lifetime. The materials will run you about $150 but everything is readily available.

There are many variations that can be built into this workbench it all depends if you want to trim and finish it out with more details. I will cover the basic bench. Nothing more then what is necessary to have a functioning work bench.

Materials List

4 - 4" x 4" x 35" Legs
4 - 2" x 4" x 80-1/2" Upper and Lower Long rails
4 - 2" x 4" x 32-1/2" Upper and Lower Short rails
2 - 2" x 4" x 34-1/2" Middle Stretcher
3 - Sheets 3/4" Standard Plywood upper work surface and lower Shelf
1 - Sheet 1/4" MDF Replaceable work Surface
32 - 1/4" x 2-1/2" Lag Screws

So let’s get started. The first step in building your work bench is to cut the 4x4's to length. Use the miter saw and trim the four legs to 35". You also should pre-drill the holes for the lag screws. Drill a 1-3/4" countersink with a 1/4" through hole. The top rails are flush with the top of the legs and centered on the legs. The lower rails are centered on the leg with the bottom edge 10" from the floor.

Cut all the 2x4's to length making sure the ends are square.

Time for some assembly.

Start by assembling the long rails and posts. With the lag screws and some wood glue proceed to assemble the two sides of the workbench, secure with screws and set aside until the glue is dry. A quick tip; get the lag screws stared so the tip is just coming out of the hole. Ready to go into the rail.

Proceed with the rest of the assembly by joining the two sides of the workbench together with the shorter rails. Glue and secure the upper and lower middle stretchers with deck screws. With will give the workbench more rigidity and add support to the lower shelf.

The surface of the workbench is made up of two 3/4" sheets of plywood. To secure the sheets of plywood together cover the surface of one sheet with wood glue and align the second sheet on top. Screw together with 1-1/4" screws. This provides a flat and stable working surface that will be easy to clamp to and hold a nail or screw well.

The 1/4" MDF is intended to take the brunt of the abuse this workbench will be put through. This is why it is secured with 9 - 3/4" deck screws and nothing more. When it becomes damaged beyond use simply replace it with a new sheet.

The lower shelf is ideal for storing tools, jigs or other wood working supplies. It is made of a sheet of 3/4" plywood and is screwed to the frame with 1-1/2" deck screws.

To finish your workbench you can either use clear polyurethane if the wood is nice and you want to preserve the look of it. Otherwise use paint to protect the surface from water and other stuff that it will be subjected to.

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