Hybrid Workbench Build – Page 2

tugnut1 · 2016-09-06T18:20:50+00:00

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 4x4's so that all of the boards were straight and consistent in thickness. (no picture) I cut all of the 4x4'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 4x4's. I started by drilling pilot holes all the way through the 4x4'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.

BMack37Member since Sep 2015Oct 6, 2016 10:34 AM CT

Damn man, that is ridiculously nice. Can’t wait to see what you build when you put that to use!

tugnut1Member since Jan 2016Oct 6, 2016 10:36 AM CT

BMack37 wrote:

Just now, BMack37 said:

Damn man, that is ridiculously nice. Can’t wait to see what you build when you put that to use!

Thanks BMack. I have a ton of projects I want to do this winter. A lot of them are shop improvements. My wife hates those. She says I spend too much time making stuff for my tools instead of making her stuff. LOL.

NordrawMember since Dec 2012Oct 6, 2016 5:48 PM CT

Nice job, That really looks good.

rfwjrMember since Jul 2014Oct 6, 2016 10:58 PM CT

John that is nice.

BMack37Member since Sep 2015Oct 6, 2016 11:44 PM CT

tugnut1 wrote:

13 hours ago, tugnut1 said:

Thanks BMack. I have a ton of projects I want to do this winter. A lot of them are shop improvements. My wife hates those. She says I spend too much time making stuff for my tools instead of making her stuff. LOL.

I know how that goes. Actually, this week at the shop I talked the owner into redoing the parts wall and front wall of the shop…we haven’t done crap for customers, maybe four diagnostics and four repairs all week…but we have reorganized and consolidated over 5,000 parts.

krutonMember since Jun 2015Oct 7, 2016 12:23 PM CT

That looks great man. Kinda makes the bench I have been sketching up to build look pretty pathetic!

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tugnut1Member since Jan 2016Oct 7, 2016 12:39 PM CT

kruton wrote:

15 minutes ago, kruton said:

That looks great man. Kinda makes the bench I have been sketching up to build look pretty pathetic!

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Feel free to copy this design if it works for you. If you have any questions, I’ll be glad to answer them as well.