Hybrid Workbench Build

Hey guys.  Sorry I haven’t been here for a while, but I’ve been really busy this summer.  Things are winding down (temporarily) and I have some time to spend in the shop.  

I have a mobile workbench/assembly table that I have used for many years.  It is very solid , but my biggest issues are its ugly, I always seem to clutter the work surface while I am working and I have to get clever with clamps to hold items where I want them.

I like the idea of a Ron Paulk bench, but I want a more traditional bench that I can use in the shop.  LIGHT BULB!  So I said to myself, why not make a hybrid version of these two tables.

I have a bunch of Douglas Fir 4X4s laying around, so I figured this would make for a solid bench.  I’m building this in two parts….the bottom/cabinet part and then the Ron Paulk top.  

Here is what I have so far.  

I started off drum sanding all of the 4×4’s so that all of the boards were straight and consistent in thickness. (no picture)  I cut all of the 4×4’s to length using the Kreg Track kit to make sure everything is the exact length.  

I marked out where all of the fasteners were to go.  I’m using 5 inch 5/16th Lag bolts to attach all of the 4×4’s.  I started by drilling pilot holes all the way through the 4×4’s.  

I then used a 5/8″ forstner bit and drilled a hole 1 inch deep so the 5″ lag bolt will sink far enough into the receiving board to give me a strong joint.

After that, I followed the original pilot hole with a 5/16″ drill bit to allow the lag bolts to slide through.

With all of the holes drilled, I cut some Rabbets to accept some 3/4″ plywood panels to box in the bottom and give the base a lot more strength.

With all of my holes drilled and rabbets cut, I ran the boards through the drum sander again.  This time with 220 grit paper….just to make them smooth. No need for this step, I just wanted to do it.

Now comes the fun stuff…assembly.  Pretty straight forward here.  Make sure everything lines up and then bolt up.  

I used a combination of pocket holes and regular screws to attach the plywood to the box.  Where I cut rabbets, I used regular screws.  Since I didn’t want to cut out the corners, I just used pocket screws to attach the ends without rabbets.  Not the most visually appealing look, but none of them will be visible in the final product.  I left the front open because I am going to install two full length, full extension drawers to hold the items I will use at the table most.

I will attach the casters next and then move onto the top and attaching the vice.

Thanks for taking a peak at what I have going on right now.

Looks good John! Missed your 2nd periscope on this by can’t wait to see the final assembly


Jimbo

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Scha-winggggggg! Awesome!!!! Best post in a while!!!!!! Looks fantastic dude!

I was able to catch one of the periscope videos you did. I like the idea where your going with on the bench though. Also nice to see you around on the forum again John.

Love seeing these things come along I think it’s safe to say we’re also benefiting from your time in the shop with you showing us your project!!

JimboS1ice wrote:

Looks good John! Missed your 2nd periscope on this by can’t wait to see the final assembly


Jimbo

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ChrisK wrote:

Scha-winggggggg! Awesome!!!! Best post in a while!!!!!! Looks fantastic dude!

DR99 wrote:

I was able to catch one of the periscope videos you did. I like the idea where your going with on the bench though. Also nice to see you around on the forum again John.

KnarlyCarl wrote:

Love seeing these things come along I think it’s safe to say we’re also benefiting from your time in the shop with you showing us your project!!

Should serve you well for ~10,000 years from the looks of it!

Sweet !!!!!

great looking bench

You do some damn nice work man, thanks for sharing. I can’t wait to see the final project.

I went to the Home Depot today and bought some 2 inch  5/16″ Lag bolts to attach my casters to the bottom of the base.  I think that I should have oriented my casters along the front edge instead of the sides.  It would make the base a little more stable.  I don’t think that I will have an issue, but if I ever do, it should be an easy fix.

Now, here is where I need some imput.

Option 1:  Should I fill the bottom section in with two full length drawers both being 8″ tall in the drawer face (smaller on the inside).

Option 2:  Do one full length drawer on the top around 8″ tall and leave the rest of the bottom open for tools with cases and some other misc items.  

I am a little torn.  I think the double drawers would look nicer, but I have a feeling leaving the bottom open would be more useful.  

Any feedback would be greatly appreciated.

Personally I would do the two drawers, you can always take a drawer out down the road if it doesn’t work or build a shelf for you tool cases, or you can build a hinged cover that appears to be a drawer and keep your cases in there… Just food for though but comes down to what will you grab below your worktop more a tool case or a drawer full of something


Jimbo

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JimboS1ice wrote:

Personally I would do the two drawers, you can always take a drawer out down the road if it doesn’t work or build a shelf for you tool cases, or you can build a hinged cover that appears to be a drawer and keep your cases in there… Just food for though but comes down to what will you grab below your worktop more a tool case or a drawer full of something


Jimbo

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Looking good John!!

I would go with the open bottom for the tool boxes. 

I’ve decided to go with two drawers in the front.  Of course, the drawer slides that I had on my old bench are too long.  I ordered two sets of full extention 100 lbs capacity drawer slides today for $13 apiece.

https://www.amazon.com/gp/product/B0000DD4AA/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

 I also ordered the rockler drawer slide jig to make installation full proof.  Since Rockler isn’t nearly as fast with their shipping as Amazon, I don’t know if I can wait until the jig gets here to install the drawers.  

http://www.rockler.com/rockler-universal-drawer-slide-jig

So, I’ve decided to make and attach the top to my bench this weekend and if all goes well, attach the end vice as well.

tugnut1 wrote:

I’ve decided to go with two drawers in the front.  Of course, the drawer slides that I had on my old bench are too long.  I ordered two sets of full extention 100 lbs capacity drawer slides today for $13 apiece.

 

https://www.amazon.com/gp/product/B0000DD4AA/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

 

 I also ordered the rockler drawer slide jig to make installation full proof.  Since Rockler isn’t nearly as fast with their shipping as Amazon, I don’t know if I can wait until the jig gets here to install the drawers.  

 



 

http://www.rockler.com/rockler-universal-drawer-slide-jig

 

So, I’ve decided to make and attach the top to my bench this weekend and if all goes well, attach the end vice as well.

tugnut1 wrote:

8 hours ago, tugnut1 said:

I’ve decided to go with two drawers in the front.  Of course, the drawer slides that I had on my old bench are too long.  I ordered two sets of full extention 100 lbs capacity drawer slides today for $13 apiece.

 

https://www.amazon.com/gp/product/B0000DD4AA/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

 

 I also ordered the rockler drawer slide jig to make installation full proof.  Since Rockler isn’t nearly as fast with their shipping as Amazon, I don’t know if I can wait until the jig gets here to install the drawers.  

 

http://www.rockler.com/rockler-universal-drawer-slide-jig

 

So, I’ve decided to make and attach the top to my bench this weekend and if all goes well, attach the end vice as well.

Oooh nice, may have to look at this for an upcoming build

Good choice on the two drawers. If you’re already worried about stability issues, a big-ass drawer with tools in it is going to be an issue. Splitting up the weight will help stability instead of making it worse.

I had the opportunity to work on my bench a little more this weekend.  Everything went pretty smoothly.

I first glued together and cut two pieces of 3/4″ sandiply plywood to make the top and then did it again for the bottom….of the benchtop.

Since I want this to look pretty decent, I added some 2″ iron on banding to cover up the plywood edges.  This went extremely well and these glue ups no look like a solid wood top.

Next I cut the long sides and middle support out of the same plywood.  I am making the sides 6″ tall.  I laid out the cutout so that there are two on the long sides and there will also be two on the one end as well.  Cutting out these holes worked best by using a 3-5/8″ hole saw for the ends and then cut the straights with a jig saw.  

Next, I rounded the edges of the holes by using my router table.  I pushed the fence all the way in the back and used a bearing bit.

I attached the sides and middle supports using just pocket screws.  I’m trying to avoid glue in case I need to replace the top in the future.

I also cut the ends, but I ran out of time, so I just set them in place to see what they look like.  I dropped the top on for a few minutes and it is extremely sturdy…..No flex at all.  I also just realized that when I go to add the end vice, I am going to have to remove about 13 inches of the middle support to allow for the screw and two guides.   Not a big issue at all.

Guys that looks awesome.  I am jealous, I wish I had the time.  Thanks for sharing.

Looks good

Coming along real nice! Missed your scope again, I’m always knee deep in something when the good scopes happen lol, keep it coming!


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This looks very promising, I wish I had the space, but it’s an older small building and I think I would need to make the casters different heights to match the floor profile lol!!!

That edge banding nice, i remember when I was younger and saw my Dad do that for the first time, thought that was so cool!!

KnarlyCarl wrote:

This looks very promising, I wish I had the space, but it’s an older small building and I think I would need to make the casters different heights to match the floor profile lol!!!

That edge banding nice, i remember when I was younger and saw my Dad do that for the first time, thought that was so cool!!

Sorry guys that its been a while since I updated this thread.  I have my bench completed now and I love love love it.  Let me catch you up to speed.  

I tackled the drawer option with this bench and I am glad that I did.  I first started off by adding a divider to make it look like a face frame.  I used some spacers and clamps to make it flush with the front and the same height on both sides.  Pocket hole in the back.

I happened to buy some clamps and rails that fit the dog holes and put them to use making the drawers.  More pocket holes.

I used the drawer glide jig to install the glides.  It worked really well on the outside of the drawer, but working from the floor made the inside of the cabinet install a little difficult.

Here is a shot with both drawers made before the drawer faces were put on.

Full extension drawer with fronts.

Final build.  I have to take a picture of the unit with the epoxy top coat I added, but here is what it looks like without it.

Beautiful work!

Great build John!


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Wow! Gorgeous work!

Really nice!!

Great job John!!

Where is the beer opener?


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HiltiWpg wrote:

56 minutes ago, HiltiWpg said:

Where is the beer opener?


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Oooo…..good idea.  I’m serious.  I know where I can get one too.

Man that’s freaking amazing??

Absolutely great work !!!

tugnut1 wrote:

Oooo…..good idea.  I’m serious.  I know where I can get one too.

 

tugnut1 wrote:

9 hours ago, tugnut1 said:

Oooo…..good idea.  I’m serious.  I know where I can get one too.

 

I did a review on a great one by Milwaukee so…. 😉

Breath taking…..[emoji106][emoji109][emoji481]


Tough Tool Reviews on Instragram

[emoji106][emoji106]. Awesome. I just made room in my shop. When should I expect delivery? Don’t worry about the beer opener, I can add that when it gets here


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Eric – TIA wrote:

[emoji106][emoji106]. Awesome. I just made room in my shop. When should I expect delivery? Don’t worry about the beer opener, I can add that when it gets here


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You’re probably right, that’s why it would be better to drive it to my house. Why should you have to pay those high shipping cost.


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One last set of pictures for this post.  I finished the top of the bench by rolling on 4 coats of West System epoxy.  I was pretty nervous about using it, but I needed to make the plywood top more solid and protect it from chipping.  I’m extremely happy with the results.  If I was good at it, I could have had a surface that looked like glass, but for Pete sake, its just a work bench.  LOL.

Ooooooh …. shiny ….

very nice

Nice job. It looks amazing


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looks good nice job!

???

Wow, the finish looks rock solid dude!

The finish looks really nice!!!

The whole workbench looks nice!!

Shiny !!!! You might have to wear your sunglasses when working on the workbench. 

Alright lets see some projects off of the workbench now.  :rolleyes: 

LarryS wrote:

2 hours ago, LarryS said:

The finish looks really nice!!!

The whole workbench looks nice!!

Shiny !!!! You might have to wear your sunglasses when working on the workbench. 

Alright lets see some projects off of the workbench now.  :rolleyes: 

  Hello Larry.  I am making some Rockler knife sets right now for my dad and son.  I will also be making some custom gift boxes for them to live in.  I just made a spline jig to help me with the boxes.  I hope to start them this weekend, so we should see some more stuff soon.  Thanks for the compliments brother.

tugnut1 wrote:

1 hour ago, tugnut1 said:

  Hello Larry.  I am making some Rockler knife sets right now for my dad and son.  I will also be making some custom gift boxes for them to live in.  I just made a spline jig to help me with the boxes.  I hope to start them this weekend, so we should see some more stuff soon.  Thanks for the compliments brother.

Will be looking forward to seeing pictures of your projects!!