The goal, as I’ve rambled on about before, was to decrease the footprint, increase the usability, make it heavy duty, include index file storage for hardware, and do it all relatively inexpensively. Simple enough.
I looked around my horde and figured I could break down this 24” deep shelving and make a bench out of it. I had modified pallet racking, before, to make a wheel and tire rack (see below) and felt like I had good results. Plus, using racking gives it the look that it hasn’t been fabricated, that it could’ve been manufactured/purchased. I don’t know why I like that but I do.
With all the stuff flying out of my shop and either being put properly into storage or sold the shelving was free to use. I figured I deal with making attic shelving, which I was going to repurpose this as, later.
Then, out of sheer coincidence a guy I knew had some 24” Interlake uprights that held a lesser capacity but worked with beams and such for $20. I couldn’t pass that up and I could leave these uprights for later use.
24” deep Interlake racking seems less common, so grabbing it made sense.
The only thing I needed to order was a bench top because I wanted to bends in it. The local steel place hooked me up. I wanted as thick as possible and they could bend some seriously thick stuff but due to the price, I settled on ¼”. Much heavier than I have ever owned, for sure.
After getting that home, I chopped up the uprights and beams. The wood was to keep everything square.
I cleaned it up and had a buddy burn them together. No welder at my place, yet. We made good time with everything ready and prepped.
I wiped the uprights with acetone and hoped for the best. The beams I had sent out to be blasted because there were stickers on them from the warehouse they lived in before me. I should have sent the uprights, too, but that’s life.
Here they are with some etching primer. It was one of our last 70 degree days of the year. Between running errands and working on the shop, I got them painted.
By that afternoon, I had something that resembled a bench.
Turns out my first mistake was measuring the height. With the top on it ended up being 7/8” higher than I wanted. I actually like the height, a lot, so it was a good mistake to make. It fit perfectly under the outlets. I love when that stuff works out.
More mocking up, still lots to go. It’s crazy how little jobs like this can drag out. I ended up with one more index card file from the guy I got the other two from, years back. Since it was missing two drawers, it never sold. We traded some items and I took this with me. Drawers were easy enough to fab.
I modified that uni-strut from my last bench. And as you see, I added a diagonal flat bar. That was my second oversight. This one was more major. Not having triangulation allowed the bench to move a lot when pushed back and forth. There wasn’t a lot of force needed, either. You could lay your hand flat on the top and wiggle it, with ease. The triangular piece stiffened it up really well.
If you look at the back of the bench, in the center, you can see what looks like a rivet head. That mounts the back of the bench top to the legs via two 1” wide 1/8” pieces of metal.
I wanted to add a hammer loop, so I looked in my scrap bin and found an exhaust clamp U-bolt. It worked perfectly. I trimmed it down just beyond the second nut so there’d be no interference.
Then, I bolted the whole dang thing together, everywhere.
The top, again, I used 2 more carriage bolts. One on each side mounting the top to the legs.
The top/center bolt. I figured it gave a smooth, riveted look and blended in better than a bolt.
I liked having the vise on the right side of the bench leaving the left as a work space. I had read a few threads with people’s opinions one way or the other. I didn’t leave those threads convinced of either view. It felt correct on the right side, to me. So, that’s where it went. Hopefully for good.
I lined the jaw up with the end of the bench. I pushed it against the front just enough the mixing stick didn’t bend.
I marked the holes and popped them in.
Having a mag drill rules. It probably took all of five minutes including set-up and cleanup. As well, having outlets where everything can be plugged in is quite the luxury that I am still growing used to. Haha.
After that, I wiped down the top, removing the oily film from it and I sprayed some wax onto it.
The last thing I needed to do before I could call it done was shim one of feet. These plastic shims are great. They break off easily and straight and there’s no trimming needing to be done. Now it sits solid as a rock.