We talk to a lot of people who are building some
sort of work bench. We have a very simple design that most people can build. We
have a few of these at our Corporate Offices for Ollie to play with. Here's his
design:
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This bench can be made any
size by using a few simple dimensions: Front overhang should not be too big as
it may tip forward so go with something that doesn't put the finished edge too
far in front of the casters; The sides and back overhang should be about 3";
standard workbench height is 36" to 38". We stand to work on ours so we like
them around 37". When designing your bench, remember to include the "overall
mounted height" of the casters. We used 5" wheels so our caster height was 6
3/16". We used our Model 3A Total Locking Plate mount caster, a RED
Polyurethane wheel with precision sealed ball bearings. Ollie can be a little
tough on these benches so when we make the top we glue and screw 2 layers of
3/4" plywood together. On top of that we screw ( no glue ) a 3/16" hardboard (
masonite ) which can be replaced when it gets damaged. By just using screws for
the top layer it can easily be replaced with another piece of hardboard. We
edged the top and the shelf with Oak and again just attached with drywall
screws. It can be taken off to be cleaned or replaced with ease. |
Materials:
( 2 ) 4" x 4"
x 8' Douglas Fir - For the sides
( 1 ) 2" x 6" x 8' Doublas Fir - For the
back "stringer" between the sides
( 1 ) 4' x 8' x 3/4" Plywood - For the Top
and the Shelf
( 1 ) 4' x 8' x 3/16 Hardboard ( Masonite ) - For the Top (
Optional )
( 8 ) 5/16" x 6" Lag Screw with Washers - Used for the
construction of the sides.
( 16 ) 5/16" x 1 1/2" Lag Screws to attach
Casters
( 8 ) 5/16" x 3" Lag Screws with Washers - For attaching the back
"stringer" & the top.
( 1 ) Box of 1 1/4" dry wall screws.
Wood
Glue
Oak or other wood to "band" the top and the edges of the shelf ( we
used oak )
( 2 ) Small side braces for the shelf.
( 4 ) Model 3A Plate
Mount Total Locking Casters
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Using the photos below, you can
figure out how it's assembled. When making the "box" sides, wood glue and Lag
screw them together. It is very important when cutting the 4" x 4" to make sure
that the ends are "square" ( 90 degrees ) otherwise your "boxes" will not be
square and level. "Let in" the rear stringer, glue and attach with lag screws.
Use the stringer as the rear shelf support. Sandwich 2 pieces of plywood
together with drywall screws and glue. The result will be a VERY strong 1 1/2"
thick top. If you have any questions, send
an email to Bill ( Ollie's Woodworker ) by clicking here.
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