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DIY Workbench

This workbench is easy to build, but built to withstand heavy use.

Difficulty: Easy
Time: 3.8–7.3 hours
Cost: $$$

Cut list

Part	Qty	T × W × L	Material	✓
Leg	4	1" × 3" × 35"	—	☐
Long Leg Filler	4	1" × 3" × 20"	—	☐
Short Leg Filler	4	1" × 3" × 8"	—	☐
Bottom Rail	2	1" × 3" × 38"	—	☐
Top Rail	2	1" × 3" × 46"	—	☐
Side Rail	4	1" × 3" × 19"	—	☐
Shelf	1	3/4" × 22" × 31"	—	☐
Sub-Top	1	3/4" × 29" × 47"	—	☐
Top	1	3" × 27" × 45"	—	☐

Materials

Item	Qty	✓
Board, 2x4 x 96"	6 board	☐
MDF, 3/4" x 48 x 96"	1 board	☐
2 1/2" Kreg HD Pocket-Hole Screws	16 each	☐
2 1/2" (standard) Kreg Pocket-Hole Screws	16 each	☐
1 1/4" coarse-thread Kreg Pocket-Hole Screws	24 each	☐
2 1/2" flat-head wood screws	40 each	☐
Kreg 27" x 45" Universal Clamp Trak Kit	1 each	☐

Overall cost: $$$. Lumber varies by region, species, and season, so we give a band rather than a figure.

Tools

Circular Saw
Drill / Driver
Pocket Hole Jig
Random Orbit Sander
Bar / Pipe Clamps — optional
Tape Measure — optional

Instructions

1. Cut Leg Parts
- Cut four Legs, and four Short Leg Fillers, and four Long Leg Fillers to length from 2 x 4 boards, as shown in the cutting diagram.
- Sand the parts smooth. Tip: Be Picky when Picking Boards The base for this bench is made from 2x4 stud lumber. These boards are inexpensive, sturdy, and easy to cut. They’re not always pretty, though. When you’re buying lumber, take your time and find boards that are straight, clean, and that don’t have torn up edges. Even if you have to spend a while digging for boards, it will take a lot less time than you’d spend sanding and trying to make bad boards look good. Plus, you’ll have an easier time building, and you’ll end up with a better-looking bench.
2. Make the Bottom Rails
- Cut two Bottom Rails to length from 2x4 boards, as shown in the cutting diagram.
- Drill 1/4"-diameter holes where shown.
- Then, with your Kreg® Pocket-Hole Jig set up for 3/4" material, drill pocket holes along one edge of each Bottom Rail.
- Sand the Bottom Rails smooth.
3. Create Leg Assemblies
- Spread glue on the back face of each Short Leg Filler, and then clamp them to the Legs so they are flush on the sides and one end. Secure each Short Leg Filler to the Leg from behind using four 2 1/2" flathead wood screws. You shouldn’t even need to drill pilot holes.
- Next, position the Bottom Rail so it’s resting on the Short Leg Fillers, and clamp it in place. Make sure the distance between the leg assemblies is correct, and attach the Bottom Rail with large screws. We used Kreg HD (Heavy-Duty) Screws.
- Now you can add the Long Leg Fillers in the same way as you added the short ones, attaching each one with six 2 1/2" flathead wood screws.
4. Make the Top Rails
- Cut two Top Rails to length, as shown in the cutting Diagram.
- Trim off the corners, as shown.
- Next, drill 1/4"-diameter holes at the location shown.
- Then, with your Pocket-Hole Jig set up for 3/4" material, drill pocket holes along the long edge of each Top Rail.

Install the bench top assembly by first positioning it, and then checking for equal overhangs at the front and back, and on each end, as shown.
Then attach the top assembly using 1 1/4" coarse-thread Kreg Pocket-Hole Screws. Install the Bottom Shelf so it fits flush with the outer edges of the Bottom Rails and the Side Rails.
Then you can apply a protective finish. We simply wiped on a few coats of natural oil finish. An oil finish is great for a bench because it’s easy to apply, it resists glue, and, best of all, it’s easy to renew. As you bench gets worn and scratched, you can just give it a light sanding, if needed, and then wipe on more oil. The MDF will soak up a lot of oil, so you’ll probably need to apply two or three coats to the bench top and shelf. One or two coats should do it for the bench base.

DIY Workbench

Cut list

Materials

Tools

Instructions

1. Cut Leg Parts

2. Make the Bottom Rails

3. Create Leg Assemblies

4. Make the Top Rails

5. Attach the Top Rails

6. Make the Side Rails

7. Attach the Side Rails

8. Make the Top and Shelf

9. Assemble the Top

10. Add the Track

11. Install the Top and Shelf, then Finish