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Dukers - Workbench Build

Duker

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Sep 25, 2010
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10,861
Location
Livingston, TX
Welcome to my Workbench build thread. I thought I would start a separate thread from my Garage Projects posts as this will be picture heavy over time and it would also be a way to document the process and to get comments and ideas as work through the build process.

This thread is also a small tribute to GJ member – Steevo whose original project spawned mine and many other imitations of his workbench. If you are considering a project like this and have not checked out his thread I would highly recommend reading all three threads of his build. If imitation is the sincerest form of flattery then you will be in workbench heaven ( a virtual “testosterone” overload ) as many folks have posted their versions of Steevo’s bench within the thread. :)

I have taken Steevo’s concept and have added my own little twists and ideas to the build. The Workbench or what I have come to call it workstations will be a series of workbenches and built in storage in various forms.

NOTE: Before I catch to much grief…. I will preface upfront that I have spent way too much money and have gone way overboard with the building of my benches. My only defense is that it has been a way for me to psychologically get through some family issues. I have a child with special needs that has needed some very expensive specialized care. The unexpected costs and the probability that these costs could go on for years forced me to postpone building my workshop indefinitely. I had been planning and saving for this for years, so as I stated before in my garage projects thread facing both stress and disappointment; I decided to take the pile of lemons now tossed in my lap and make one huge *** margarita in an effort to give me something else to focus on and thus the birth of the workbench build. Taking some of my planned budget for the workshop I splurged on the workbenches and steel for the storage units.

So onto the build….

Stage one was the building of an original Steevo style bench but using two HF 56” cabinets instead of the 44” cabinets. Eventually there will be two sections of these benches. I chose the 56” cabinets because when I measured the various drawer heights I found the 56” better suited in my case for storing items like my collection of hand planes and other assorted woodworking tools.

Here is the frame after being primer-ed:

Workbench06.png


After painting:

Workbench07.png


Dropping the first cabinet into the frame with my engine hoist.

Workbench08.png


Placing it close to its final parking spot. You will notice the Blue walls have been painted gray to better go with my new paint scheme for the garage. As I moved some cabinets or tools I would paint a section at a time. The reason for the color change is that I am colorblind to some colors and my wife would remark (quite often) about how dark the color blue I picked for the walls were so I decided to change to a Red, Black & Gray scheme since I could see those colors and it would make the boss happier. My apologies to the diehard Ford guys!

Workbench09.png


Next on the list was a corner cabinet. I was trying to think of how I could utilize some of the dead space of the corner so I came up with a corner cabinet design using the HF 7 drawer side chest. While the design does give you additional storage it eats up a total of 38” inches on both side so the jury is still out on whether the additional storage is worth the loss of wall space. For me, I am going to build and upper cabinet to hold a flat screen tv so proportionally it should look good.

Here is the beginning of framing for the 7 drawer chest.

CornerUnit05.png

CornerUnit02.png


Here is the completed cabinet after priming:

CornerUnit04.png



The completed corner cabinet:

CornerUnit1.png
 
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Duker

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Sep 25, 2010
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Location
Livingston, TX
It was time to shift gears, as I needed to move some Rousseau cabinets I had bought at auction a few years back to make room for the workbenches and Hutch that was in progress. Rousseau cabinets are very similar to Lista or Vidmar cabinets in their quality of construction. The cabinets I had were used in a warehouse rack configuration, which meant there were no cabinet doors to hide the contents nor any leveling mechanism which I needed to account for my sloped garage floors.

Here is the external frame being welded up. The Cabinets are made from 2” x 3” 12 gauge tubing and are 93” tall not including the leveling feet.




RousseauFrame02.png



Here I am laying out the drawer glide mounting brackets:

RousseauFrame03.png


I used these ¼” welding T nuts to mount the drawer hardware to the frames:

RousseauFrame05.png


Here is a view of the sides and back of the cabinets. These will be either against a wall or against one of two hutches I am building so I didn’t enclose the back of the cabinets.

RousseauFrame06.png


Here is a completed frame standing next to one of the original cabinets.

Rousseau.jpg


Here is the completed cabinet with the upper cabinet installed:

Rousseau10.png


Here is a close up of the door construction. The doors are poplar with a MDF center panel offset in the frame for a ¼” reveal which gives the doors some detail but kept construction easy. I was pressed for time and didn’t seal the MDF first before priming and painting so I am not happy with the door finish but I will reshoot the doors when I paint the rest of the cabinets.

Rousseau09.png


Here is a shot of the interior of the cabinets. Some of the cabinets will be center divided as this one and others will have full open shelving. I have 4 – 24” deep and 5 – 18” deep cabinets. So…. One down 8 to go….

RousseauFrame7.png
 
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Duker

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Sep 25, 2010
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Livingston, TX
It was time to head back to working on the hutch. I bought one of the 72” HF tool chests planning to use in a hutch but I was waffling on how I was going to incorporate the features I wanted into the build.

HF72ToolChest.png


This is what I came up with for the first hutch…. Again 93” tall with three sections. The first section on the bottom is for the tool chest. The middle section will have a Maple top work surface and will have metal slatwall for three sides of the interior and two sides of the exterior. The top section will have a custom cabinet that will have LED lights on the bottom and two flip up gas hinged doors for additional storage.

Hutch01.png


Here is the completed cabinet frame being prepped for paint. The metal panels on the back are so if I ever decide to make it free standing you wouldn’t see the slatwall from the back.

Hutch02.png


Here I am finishing the wiring for the junction box, lights, light switch and plug.

Hutch03.png


Here is the completed frame painted:

Hutch10.png


And here is the back with the 72” HF tool chest installed.

Hutch06.png


I will post some more pictures of the hutch when I get back from a little vacation.
 
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dr_clyde

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Jan 7, 2009
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Holland, MI
The HF boxes are truly the best bang for the buck in storage. Nice work. Looking forward to the finished product. Keep up the good work and keep fighting the good fight!
 
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Duker

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Livingston, TX
Thanks guys. Progress has been slower than I like as my shop time has been limited this summer. I am hoping to get some more done over Labor Day weekend when I get back into town.
 
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Duker

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After about 3-4 weeks of trying to find some time to get into the shop I was finally able to squeeze in a few hours and finish up the hutch. Here is the back of the hutch with the top cabinet completed and installed.

Hutch11.jpg


The wooden top cabinet is attached at all for corners with screws counter sunk into the 1/4 plate angle brackets.

Hutch12.jpg


Here is the underneath of the cabinet where I installed some recessed puck lights. I had originally planned on using some LED lights but I had three units in a row that I purchased from both Lowes and Home Depot that were bad so I threw in the towel and installed the Halogen lights.

Hutch13.jpg


I decided to go with a maple top as I will have some steel tops on the main benches. I think from an visual point the steel might have gone better with the hutch but from a time and resources standpoint I am committed now. The metal slat wall is installed on all three sides giving me plenty of tool storage options. I will be working on some custom tool holders over the next few weeks.

Hutch14.jpg


I installed a switch and a plug into the slat wall.

Hutch15.jpg


The upper cabinet has two lift up doors that will have some spring loaded hinges once I can find some time to install them. For now however, its nice just to have a spot to stick manuals and assorted books etc..

Hutch16.jpg


The ends of the cabinet have slat wall as well. I also added a swinging arm Reelcraft power reel to the top of the cabinet to give me some flexibility in have access to power.

Hutch18.jpg


Since the HF tool cabinet is slid into place and not dropped into place like a traditional Steevo model I wanted some way to keep the cabinet from potentially sliding out backwards. I used the tapped holes where the handles were to create a "jam lock" with a piece of 16ga tubing. No risk of the cabinet sliding now but still easily accessible if I need to remove the cabinet for moving.

Hutch19.jpg


This picture starts to give you an idea of how I am using the cabinets to divide the garage and create distinct work areas and storage. The Rousseau cabinet on end will actually be slid down and against the wall. Two other cabinets one with a closed panel end will replace it to finish off the looks.

Hutch20.jpg


Sorry that I couldn't get a better picture of the whole cabinet but I am running out of floor space where I have been stacking things to make room for the cabinets as I complete them.

Hutch17.jpg


The hutch was a fun project. While designing the project in my mind I figured out ways to build a sliding locking door that could be used to lock the slat wall area of the hutch. I decided not to go that route however as it would have meant a smaller size and I really don't have the risk of tool loss as those of you in public shops. If I decide to build a mobile version ( I need to figure out what to do with the wheels from the HF tool chest) I will go that route.

Hopefully up next will be the tall corner cabinets that will finish off the ends and will have a 7 drawer chest and the HF end cabinet installed in them.
 
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Duker

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Amazing... very cool...

Thanks Jason. I am going to take a little break from the work bench build and start my restoration of the vice i got from you. Keep an eye out for it! :)

Wow!! Top notch work!!! Where did you buy the metal slatwall?

Thanks Sean. I got the slat wall from MegaWall. I wanted metal since I knew I would be taking tools off and on quite a bit. I had metal reinforced slat wall that was a MDF core previously in another garage and it did not hold up well so I went this route for this project.

Its not cheap and the shipping can kill you. I went in with a couple of friends on an order so we split the shipping cost which made it more bearable but still ate a chunk out of my budget.
 

cagullett1

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Sep 29, 2013
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North Texas
Amazing work! I've been eyeing a 6' long Equipto cabinet, the same style as your Rousseau's. What made you decide to build a new frame for it, rather than enclosing the top of the original frame and adding leveling feet. Am I seeing it right, that you backed the hutch up to the Rousseau cabinet? Also, what paint did you use to match the HF box so well?

You have a TON of storage between the Rousseau's, hutch, 56" HF boxes (how many of those do you have at this point?), and the 5 drawer cart!
 
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Duker

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Livingston, TX
Amazing work! I've been eyeing a 6' long Equipto cabinet, the same style as your Rousseau's. What made you decide to build a new frame for it, rather than enclosing the top of the original frame and adding leveling feet. Am I seeing it right, that you backed the hutch up to the Rousseau cabinet? Also, what paint did you use to match the HF box so well?

You have a TON of storage between the Rousseau's, hutch, 56" HF boxes (how many of those do you have at this point?), and the 5 drawer cart!

Thanks. I looked at modifying the existing rack but there is not much of a foot to weld to for leveling and the metal is pretty thin gauge. In addition making doors work proved to be a challenge as to the way the shelves are attached. Also you would be forced to keep them in pairs at a minimum due to that is the way you get rigidity. By having a stand alone cabinet it gives me flexibility in where I can put them and also how I want to configure the upper cabinets.

I do have a lot of storage with 5 - 18" deep and 4 - 24" deep Rousseau cabinets. I now have three 56" HF cabinets (two in one bench) one 56" top box and now the 72" in the hutch. That said I have 4 of the Rousseau cabinets full up in hardware alone (bolts, nuts, handles, etc.) that I got from a hardware store that was closing. The long term plan called for another bench with two 56" cabinets in it but that was going to be when I built my new shop. Unfortunately that is on hold indefinitely.

The paint is Krylon Banner Red. The spray can is a closer color than the quart can for some reason so I have my local Ace tint it when I spray and then if it needs it rattle can a color coat.
 

MillerMav

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Feb 6, 2013
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269
Very cool build! Such awesome attention to detail and implementation of ideas.
 

Hot Chop shop

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Apr 12, 2013
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Las Vegas
Your new setup looks great but I fear you no longer have room for your welding table. I would be happy to hold on to it for you :)
 
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Duker

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Livingston, TX
Your new setup looks great but I fear you no longer have room for your welding table. I would be happy to hold on to it for you :)


I am going to have to hold onto it for a little while longer as I have a few more cabinets to make!

I am going to start on the corner cabinets in a couple of weeks. I think you might like those as they could be an option for your bench setup down the road.
 

OJ Bartley

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May 18, 2009
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605
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Toronto, ON
Awesome work, Duker. The framing and cabinets really look great together, and I can't wait to see this finished project.
 
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