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This custom workbench was designed to incorporate the Kreg Trak system and Bench Clamps.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| End Apron | 2 | 2" × 6" × 32 1/4" | — | ☐ |
| Side Apron | 1 | 2" × 6" × 47 1/4" | — | ☐ |
| Bottom Frame | 1 | 2" × 6" × 47 1/4" | — | ☐ |
| Table Leg | 4 | 2" × 6" × 33 3/4" | — | ☐ |
| Outside Leg Support | 2 | 2" × 4" × 29 1/4" | — | ☐ |
| Inside Leg Support | 1 | 2" × 4" × 50 1/4" | — | ☐ |
| Side Apron | 1 | 2" × 4" × 47 1/4" | — | ☐ |
| Bottom Frame | 5 | 2" × 4" × 20 1/4" | — | ☐ |
| Bench Top | 1 | 3" × 24" × 45" | — | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| Board, 2x6 96" | 4 board | ☐ |
| Board, 2x4 96" | 4 board | ☐ |
| Plywood, 3/4" Thick Quarter Sheet | 1 board | ☐ |
| 45" Kreg Trak | 1 each | ☐ |
| 27" Kreg Trak | 1 each | ☐ |
| 3" Kreg Bench Clamp | 1 each | ☐ |
| 6" Kreg Bench Clamp | 1 each | ☐ |
| Kreg Clamp Vise | 1 each | ☐ |
| 1/4" hex head machine bolts at 2.50" | 18 each | ☐ |
Overall cost: $$$. Lumber varies by region, species, and season, so we give a band rather than a figure.
Cut the quarter sheet of 3/4" plywood to 24" x 45". Leaving the frame face down, dry fit the Kreg Trak and sheet of plywood. Following the provided image, the Trak requires an empty space at the end of one side to allow the clamps to slide into place. Because the plywood is cut to 24", there will be a 3" gap at the back of the work surface that will be used for a later step.
When you flip the bench top over, there is a bonus (inset) 3" space at the back of the bench. You can use this for storage or cut out a slot for speed clamp access. Cut pilot holes of the desired width (be mindful of existing pocket holes and screws) and use a jig saw to cut a desired groove. I rounded the edges of the slot over with a router and a roundover bit.
This bench is made for a tall person (I'm 6'5") and the bench top height is 36". I cut (4) 2x6's to 33.75" and attached with 1.50" pocket holes and 2.50" pocket screws.
Using a 3/4" forstner bit and a drill, drill bench dog holes at desired spacing. These holes universally accept all bench dog accessories like Kreg Bench Dog stops and Rockler Bench Cookies.
Using the Trak template evenly space pilot holes for the mounting bolts. Be careful not to drill through existing pocket screws. Drill 5 pairs along the 45" Trak and 4 sets for the 27" Trak.
You won't be able to follow Kreg's instructions for the install because the material is thicker than the 3/4" recommended for the machine screws they include. Instead, thread insert the 2.50" 1/4" machine bolts hex head first into the Kreg Trak and then feed through the pre-drilled holes. With the bolts lined up with the holes, you should be able to push the Trak straight down into place. If you need to, you can use a rubber mallet and a scrap piece of wood to gently tap the Trak down.
Using the washers and 1/4" nuts provided by Kreg, secure the 2.50" bolts underneath the benchtop. This is where hole placement becomes important. The washers and nuts should fit with enough room to tighten with a wrench. Be careful not to over tighten and damage the Trak.
Pick a spot for the Kreg Clamp Vise, drill pilot holes and attach with provided screws.
Adding a finish to the bench is completely optional. I used MinWax Espresso for the stain and discount green paint from the hardware store for the trim. After the paint dried on the trim, I sanded off 25-35% with 80-100 grit sandpaper and then smoothed over the entire project with 220 grit. I then applied the stain over top the paint and wiped off the excess for the antiqued effect. I finished the entire work surface several coats of MinWax semi gloss poly.