work benches... from scratch

[brianh]

I like to use flap grinding disks for cleanup work on metal.

 

[longboy515]

x2 on flap discs, much easier to use without grinding too far.

 

[daveroy]

ok, Here is the bench I inherited from my grandfather. The first nail I ever drove was on the floor next to this bench, I was probably 5 years old. I acquired it when Grandpa passed back in '95.

There's an actual picture (needs some straightening!) and a sketchup rendering I did just goofing around.

 

[Wingnut65]

Nice solid bench and beautiful carving. I wish I had talent like that.

 

[sbhockey]

A friend dropped this off last night for free - I've already spent 20 minutes grinding on the top in hopes of getting it down to nice shiney steel - so far I've knocked off the worst of the grease paint and rust - but I have a long way to go.

Any recomendations on grinding discs for this task?

sorry for the low quality cell phone pic:

If you were closer I'd say bring it to my work. I could have the whole thing cleaned up and dead flat in about 15 - 20 min. We have a 36" x 160" linear blanchard grinder.

 

[Grouper]

Here are some pictures of my buddy helping me build my bench. Its a long and skinny 2x8 bench, because im working in a "smaller" 19x20 garage, and didnt want anything to wide sacrificing my already small width!
Since the photo's, ive added a 5th leg half way across the back of the bench, and bought 5 nice HD casters. Ive also bought a 1'' piece of ply that i ripped in half, and am using as a work top, untill a piece of 1/2 or more steel plate shows up a decent price....
Enjoy!!

 

[Grouper]

Here are some pictures of my buddy helping me build my bench. Its a long and skinny 2x8 bench, because im working in a "smaller" 19x20 garage, and didnt want anything to wide sacrificing my already small width!
Since the photo's, ive added a 5th leg half way across the back of the bench, and bought 5 nice HD casters. Ive also bought a 1'' piece of ply that i ripped in half, and am using as a work top, untill a piece of 1/2 or more steel plate shows up a decent price....
Enjoy!!

 

[chief ben]

I built this for my lathe. 2x4 legs / plywood sides and bottom screwed to legs / pegboard sliding doors. There are only 4 2x4 legs 2x4 across top and bottom on front and back, no other framing and it's plenty strong to hold a 600 lb machine

That Lathe looks just like my 1979 Jet Lathe, is it a Jet and what year is yours??

 

[milner351]

If you were closer I'd say bring it to my work. I could have the whole thing cleaned up and dead flat in about 15 - 20 min. We have a 36" x 160" linear blanchard grinder.

I wish I was too! oh well - I'll just have to do it manually - being perfectly flat isn't likely - this thing appears to have a bit of a bowl shape to it - but again for the price, I can't complain. It gives me a chance to try out a few different grinding wheels / discs too... always learning something.

 

[R6rider]

Grouper, I like that bench... good job. i built my first one of wood, but my next one will be with metal like yours.

 

[throttlejunkie1]

New guy here. I've been lurking from time to time reading and searching the forum for useful information.

I have a long list of "to do's" for our new house. Of course the garage is always a place of business and leisure. Its the best of both worlds! Among paint, floor coating, lights, power outlets, and other common upgrades I plan to do this year, here is my newest addition. Scored some cheap kitchen cabinets from a friends neighbor doing a kitchen upgrade. Also, took home about a half ton of free lumber from work that they were gonna throw away and turned it into a work bench:

Some of the wood:

The left overs:

Plus some additional 2x4's not in the pics above. I built this: 96w" x 22d" x 36t"

Not quite done yet. Still have to frame the sides, istall shelves, and cabinet doors.

 

[78Staff]

Because I have a sloping garage floor, I was thinking about doing something similar to scott_one's setup here... which seems like the best solution, ie level the top frame secure to wall and built down (and up) from there. I also want to make room for several CM lowers as well.

I did think of something like this setup from nkachur... I like the clean layout of the bottom with the integrated chests, but have decided against it. For one it would probably take more skill than I have , and two I will probably change my lowers in the future which would nix the whole design

I also looked at the various kits, ie 2x4basics, but don't see an easy way to level other than shimming which I don't think would work out well over time.

So I think I am going with the first design, generally, but beefed up a bit with 2x6 frame for the bench maybe and adding sistered supports front and rear. Then add backwall, etc and maybe a bit of shelving also...

 

[Daddy_Rabbit]

where would one find the clips that are holding the ratchets and extensions on the flip-up top on nkachur's bench?

 

[srmofo]

well here is a few pics in progress of mine. I also have a sloped floor, but wanted a level top. I just built the top and held it in place with my jaw horse. From there I started measuring. The first bench was a breeze. My second corner bench took some thinking. Im still not completely done with whole mess but its getting close.

Any recommendations or ideas on how to attach the top. Right now Ive got the bottom layer of 3/4 partially screwed in and the top is just laying there. I want the top to be replaceable so glue is out. Im thinking just a bunch of screws. I dont really want them hidden (ie, from the bottom)because if I am drilling, cutting, or attaching things I want to try and avoid the fasteners.

Here is the first bench. I plan on enclosing it as well and thats why the channel is left at the bottom of the legs. Im going to rip 2 grooves and drop another 2x4 in. I tried on my buddies little table saw and it just didnt have enough *** to get the job done so I have to dig mine out. The bottom shelf is also recessed back to avoid kicking.

 

[srmofo]

The second bench has a spot for me to sit at with a heavy duty work area. Theres also some storage underneath at the corner. I was originally going to build a corner shelf into it, but decided on building a corner shelf and hanging it on the wall with french cleats. It wont bounce everything around if Im beating on the table and honestly this thing is starting to get a little too heavy.

It is mostly enclosed from 1 piece of 1/4 osb. There is a 1.5" gap at the top on the back side, but i figure it lets some fresh air and light in. Plus i cant see it unless Im laying on the ground. Im thinking Im going to add some shelving into the storage areas but Im going to wait until I need it.

I also plan on cutting the legs down even and adding leveling feet if I need to move it to another area. Ive found some decent ones at mcmaster, but I thing I decided on hockey pucks and some 5/8 bolts. mcmaster part number 62805K44 if anyone is interested at $5 each Ill have just about as much in my home built ones.

 

[OGJordan]

Think this is my first post here, but I threw together a bench a couple days ago for my shop (30 x 30) at our new house.

4x4 legs, 2x4 everything else. Start of the framing (added a couple cross braces under the top after I took this pic) Hard to see, but the short stringers at the top are set into notches on the 4x4s:

Didn't take any progress pics. The top 2x4s are only 7' and the top is 8' so I have 6" free and clear on all sides at either end for clamping, and about 18" til it hits the main structure so I can clamp/add anything I need at the ends.

The top is made of Oak plywood. It's 2 sheets of 3/4" 4'x8', each cut into sections of 32" and 16". There's a layer of 32" topped by the two pieces of 16" side by side, with the second 32" wide piece on top of that. All glued together, the bottom 32" sheet is screwed to the base every 10" or so, the 16" pieces are screwed through the bottom sheet and into the structure also about every 10", just offset from the screw on the bottom piece.

The top piece of 32" Oak is put on with minimal screws (still glued and clamped though) to keep it a bit cleaner looking. So the top ends up being about 2 1/4" thick Oak plywood. The edges are trimmed out with 2.5" wide 1" thick oak strips to so it looks more finished. Gonna cover the top in either Hardboard or metal, not sure yet. In laws own a fabrication shop, so the price will be low on the metal if I go that way.

Still need to put some kind of shelving on the bottom and maybe some diagonal 2x4s on three sides to strengthen it more. Thinking of doing 2x4s across the bottoms (short way, framing still, maybe 6" on center) instead of plywood so it doesn't stay as dusty and grimy under there. Will probably use that to store extra lumber.
I've got a couple sets of scaffolding casters I want to add to the table in a way that they are removable. That way I can move it but still have the stability of the legs sitting where ever I put it when I really want to hammer on it.

Bench ended up like 33.5" x 97.5" with the trim.

 

[peelman]

I also plan on cutting the legs down even and adding leveling feet if I need to move it to another area. Ive found some decent ones at mcmaster, but I thing I decided on hockey pucks and some 5/8 bolts. mcmaster part number 62805K44 if anyone is interested at $5 each Ill have just about as much in my home built ones.

Props on the corner bench. Very nice work. And thanks for the McMaster idea, I wasn't aware of them until now; after spending 20 minutes on their site I now have a go-to place for the weird **** i can't find locally (like 1/2" T-nuts... still looking for 3/4" T-nuts...)

 

[milner351]

Why use oak plywood if you're going to cover it with metal! Oak is too pretty to cover.

 

[OGJordan]

It won't stay pretty long lol. What you don't see in the other half of the garage is a car torn apart (you can see the engine and a hood in the pics) Guess I could stain it though? It will have grease, oil, and hydraulic fluid all over it at different times, want to be able to clean it up fairly easy.

 

[milner351]

I would think a few coats of a good urethane would seal it up nicely and prevent any fluids from staining it.

I'm pretty frugal - if I was going to cover the surface - I have used a cheaper substrate.

Thanks to this board though I am going to swap out the osb for plywood for my toolboard over my relocated work bench - sinc so many guys have pointed out OSB doesn't hold screws well over time.

 

[OGJordan]

Yeah, I like the oak because it's harder. Doesn't really flex as much. It's only like $45/sheet, so you wouldn't really save much. And in 5 years when I put a miss a hit and put a hammer through the top, that $50 I saved won't be what I'm thinking of.

 

[srmofo]

Props on the corner bench. Very nice work. And thanks for the McMaster idea, I wasn't aware of them until now; after spending 20 minutes on their site I now have a go-to place for the weird **** i can't find locally (like 1/2" T-nuts... still looking for 3/4" T-nuts...)

Ive ordered lots of things from them and never had an issue with anything. Great company to deal with.

I only wish they had better pictures of the actually product and not just measurements. I might have pulled the trigger on their feet if I could see what they look look like and not just the generic pic they have at the top.

 

[peelman]

Ive ordered lots of things from them and never had an issue with anything. Great company to deal with.

I only wish they had better pictures of the actually product and not just measurements. I might have pulled the trigger on their feet if I could see what they look look like and not just the generic pic they have at the top.

Agreed. I'm debating if i want to cut new front legs for my bench with a set of 1/2" feet and their T-nuts in mind, instead of the allthread/2x4-foot combo i have now.

My biggest problems are keeping the feet attached to the legs when moving the bench around and keeping the feet from rotating out of alignment. I ended up having to pin the allthread in place with a woodscrew into the side of the leg; which makes adjusting a lot more work than it really needs to be. And I added a 2x to the back of the foot up onto the existing leg, which makes it a bit easier, but still a pain.

So yeah, I have $27 of **** in my cart there, I may pull the trigger on that shortly...

 

[Lynnhowlyn]

Subscribed - so's I don't lose track of this tread and the great ideas contained herein.

Just about ready to tackle workbenches as part of the shop remodel .....

Lynn

 

[Cheesehoff]

I think I did something pretty original

and maybe not too wise.



Two part epoxy over some of my favorite old sports cards. Hopefully they weren't worth too much.

They holes in the front are to bolt on a shelf to hold my miter saw. The top and shelf were originally made with 2x6 tongue and groove left over from building our house. It's a tank.

 

[GTAHVIT]

Subscribed..

After seeing some of the work done here, I may be able to build a few benches and shelves with the scraps left over from the house

Edit:
NOT to say this stuff is scrap... LOL just that I don't need a ton of material to make some sound stuff..

 

[jeffk14]

Re: I think I did something pretty original

and maybe not too wise.



Two part epoxy over some of my favorite old sports cards. Hopefully they weren't worth too much.

They holes in the front are to bolt on a shelf to hold my miter saw. The top and shelf were originally made with 2x6 tongue and groove left over from building our house. It's a tank.

You know Cheese, I like the concept, but I'd have rather seen it done for a bar or something, say in a game room or "man cave" type of environment, not a work bench.

The reason I say that is that, in spite of my best intentions, my work benches tend to get the hell beat out of them eventually. I wouldn't want to beat on that.

 

[Cheesehoff]

Thankfully

I bought way too many cards as a kid, I could probably build a couple more benches without digging deep in the collection. And you're right, it will look great in a bar top.

 

[Rockerbox1]

Figured I would contribute a 3' by 4' roll around with a butcher block top I built this weekend. Still need to coat it with urethane.

this is nice looking. and I agree, almost too nice for a garage workbench. Planning on making something simmilar to that for my kitchen in the near future

Great job

 

[billcole]

this is nice looking. and I agree, almost too nice for a garage workbench. Planning on making something simmilar to that for my kitchen in the near future

Great job

It was cheap to build and I enjoyed doing it. I look at stuff for my garage as good learning experience for making higher quality items for our house. Basically did the same thing with cabinets. After I got it perfected for the garage I started making them for my house and my in laws cabin. This was a learning experience for building one for our kitchen, just a little smaller.

 

[peelman]

I tend to do that too; build a "draft" model of something for myself to work out the kinks then a final copy for somebody else. Its usually cheaper for me to build something out of scrap or cheap pine than it would be to mess up some nice oak or something trying to cobble something together.

 

[JohnMcD348]

Here's my Reloading bench I built using the plans from Hammerzone.com. I built it slightly larger and added a shelf and enclosed lockable area for secure storage. All materials were 2x4 and a Sheet of 3x4" plywood I had left over from Hurricane preparedness a few years back. I plan on doing a similar but larger/modified build soon for my Garage work benches but using 4x4 for the legs and 2x6 for the primary top forms.

I have a thread I started to get input on my plans also that's panned out pretty well.
http://www.garagejournal.com/forum/showthread.php?t=90610

 

[throttlejunkie1]

90% finished with my completely recycled wood workbench! Just awating paint. I dont want to start gathering supplies yet until I get back from deployment.

 

[PCO6]

I've mentioned my bench on here before but realized I have never posted any decent pictures of it. The top is 10' feet long and it's 30" deep. It's made of 1/8" thick steel and has a 4" drop at the front and a 4" backsplash. The structure is made of pallet racking which took about 2 minutes to put together. I put 10' lengths of 2" x 10"'s on top of the racking and the metal top sits on top of that. Pallet racks are incredibly stong and provide a lot of open space below for storage. No fasteners or welding were required and it's not bolted to the wall or floor. This thing is solid, heavy and won't move. I have 3 roller cabinets (w/o wheels) underneath that I still have to line up and level off a bit better. I've had this set up for the last 30 to 35 years and it's been great.

 

[48James]

Just built my work bench.

[/IMG]

 

[OGJordan]

Think this is my first post here, but I threw together a bench a couple days ago for my shop (30 x 30) at our new house.

4x4 legs, 2x4 everything else. Start of the framing (added a couple cross braces under the top after I took this pic) Hard to see, but the short stringers at the top are set into notches on the 4x4s:

Didn't take any progress pics. The top 2x4s are only 7' and the top is 8' so I have 6" free and clear on all sides at either end for clamping, and about 18" til it hits the main structure so I can clamp/add anything I need at the ends.

The top is made of Oak plywood. It's 2 sheets of 3/4" 4'x8', each cut into sections of 32" and 16". There's a layer of 32" topped by the two pieces of 16" side by side, with the second 32" wide piece on top of that. All glued together, the bottom 32" sheet is screwed to the base every 10" or so, the 16" pieces are screwed through the bottom sheet and into the structure also about every 10", just offset from the screw on the bottom piece.

The top piece of 32" Oak is put on with minimal screws (still glued and clamped though) to keep it a bit cleaner looking. So the top ends up being about 2 1/4" thick Oak plywood. The edges are trimmed out with 2.5" wide 1" thick oak strips to so it looks more finished. Gonna cover the top in either Hardboard or metal, not sure yet. In laws own a fabrication shop, so the price will be low on the metal if I go that way.

Still need to put some kind of shelving on the bottom and maybe some diagonal 2x4s on three sides to strengthen it more. Thinking of doing 2x4s across the bottoms (short way, framing still, maybe 6" on center) instead of plywood so it doesn't stay as dusty and grimy under there. Will probably use that to store extra lumber.
I've got a couple sets of scaffolding casters I want to add to the table in a way that they are removable. That way I can move it but still have the stability of the legs sitting where ever I put it when I really want to hammer on it.

Bench ended up like 33.5" x 97.5" with the trim.

Why use oak plywood if you're going to cover it with metal! Oak is too pretty to cover.

I would think a few coats of a good urethane would seal it up nicely and prevent any fluids from staining it.

I'm pretty frugal - if I was going to cover the surface - I have used a cheaper substrate.

Thanks to this board though I am going to swap out the osb for plywood for my toolboard over my relocated work bench - sinc so many guys have pointed out OSB doesn't hold screws well over time.

Got a few coats of stain on the top, still wet in the last two pics:

 

[R6 Racer]

Nice looking bench OGJordan I would use 3/4" plywood for your bottom shelf. Slide it straight in & screw it down all around the edges. It's cheep & will add a lot of stability to the bench as well.

Steve

 

[bazzateer]

where would one find the clips that are holding the ratchets and extensions on the flip-up top on nkachur's bench?

You must have hardware places over there with something like this:
http://www.screwfix.com/prods/11823/Fixings/Tool-Clips/Tool-Clip-Selection-Pack-100-Pieces

 

[Rocketman928]

Get 4drawers from office desk
2-1/2"x2-1/2"x1/8" angle welded perimeter frame to sit them in
4 locking casters
3/4" ply wood on top
Cost me about $140 in total

 

[milner351]

OGJordan - Nice work!