Post on 04-Jun-2018
8/13/2019 Workbench Preview
1/27
www.BobsPlans.com
Workbench Plans Free Preview
This free preview contains twenty six pages from our complete Workbench plans.
With this free preview, you can seethe details of building the workbench.
To purchase the complete plans with detailed parts drawings, li k here.
Copyright 2006 by Robert E. Reedy All Rights Reserved
This document may not be reproduced in whole or in part without the express written consent of the author.
http://www.bobsplans.com/http://www.bobsplans.com/http://www.bobsplans.com/http://www.bobsplans.com/http://www.bobsplans.com/http://www.bobsplans.com/8/13/2019 Workbench Preview
2/27
Table of Contents 1
Dimensions Drawings
Materials List 1 ..................................................................................................... x
Materials List 2 .................................................................................................... xi
Cutout Drawings Base/Back ................................................................................. xii
Cutout Drawings Top ........................................................................................ xiii
Cutout Drawings Panels ..................................................................................... xiv
Cutout Drawings Misc ........................................................................................ xv
End and Center Panels .............................................................................................. 1
Base Dimensions & Layout ..................................................................................... 2
Back Dimensions & Layout ..................................................................................... 3
Top Dimensions & Layout ....................................................................................... 4
Sub Top Dimensions & Layout ............................................................................... 5
Top Trim and T-Track ............................................................................................. 6
Drawer Slides, Stiffener, Misc. Small Parts ............................................................ 7
Drawer Fronts, Front Trim, and Doors . ................................................................... 8
Drawer Boxes Dimensions . ..................................................................................... 9
Middle Shelf .......................................................................................................... 10
8/13/2019 Workbench Preview
3/27
Table of Contents 2
Assembly Instructions
Drawer Slides - Left Section - Left Panel .............................................................. 11
Drawer Slides - Left Section - Right Panel ............................................................ 12
Drawer Slides - Center Section - Left Panel... ....................................................... 13
Drawer Slides - Center Section -Right Panel ......................................................... 14
Drawer Slides - Right Section - Left Panel ........................................................... 15
Drawer Slides - Right Section - Right Panel .......................................................... 16
Base to Panels ......................................................................................................... 17
Stiffener - Casters ................................................................................................... 18
Attach the Back ...................................................................................................... 19
Assemble the Face Frame ...................................................................................... 23
Attach the Middle Shelf ......................................................................................... 20
Assemble the Face Frame ...................................................................................... 21
Attach the Face Frame ........................................................................................... 22
Attach the Leveling Blocks to the Panels .............................................................. 23
Attach the Front & Rear Leveling Blocks ............................................................. 24
Attach the Sub Top ................................................................................................ 25
Attach the Inner Trim ............................................................................................. 26
Attach the Middle Trim ......................................................................................... 27
Attach the Top ........................................................................................................ 28
Attach the Track to the Top ................................................................................... 29
Attach the Track to the Front & Ends .................................................................... 30
Attach the Lower Trim ............................................................................................31
Assemble the Drawer Boxes & Fronts ................................................................... 32
Attach Cabinet Doors ............................................................................................. 33
Attach Middle Door trim ....................................................................................... 34
Clamping System Parts .......................................................................................... 35
Assemble the EZ Mount Stop ................................................................................ 36
Clamping System Usage Instructions .................................................................... 37
Clamping System Illustrations ............................................................................... 38
Clamping Long Work Pieces ................................................................................. 39
Snapshots................................................................................................................. 40
8/13/2019 Workbench Preview
4/27
45
691/2"
45
1stFront&
BackSubTopT
rim(2Required
)
1 1/2"
TheSub
Toptrim
ism
adeof3/4"
thickby1
1/2"hig
hmaterial.T
hisbec
ause
theT-Trackis1/2
"by3/4".
45
211/4"
45 1
stEndSub
To
pTrim
(2Required)
1 1/2"
45
71"
45
1 1/2"
2nd
Front&
BackSubTop
Trim
(2Required)
45
45
22
3/4
"
1 1/2"
2nd
EndSubTopTrim
(2R
equired)
TheT-Tra
c
ktrim
ism
adeof1/2"thick
by3/4"highm
aterial.This
becausetheT-Tr a
ckis1/2
"b
y3/4".
3/4"
45
45
FrontT-TrackTrim
(1Required
)
72"
3/4"
45
45
233/4"
End
T-TrackTrim
(2Requir
ed)
351
/2"
FrontT-Tra
ck(2Required)
EndT-Track
(2Required)
23
1/4"
Ifyouhav
eapoc k
et
holejig,Irecc
ommend
drill
ing
poc
ket
hole
sinthe2ndSubTop
Trimpiec
es
asshow
n.
The
sepoc
ket
hole
swillbe
usedtosecurethe
ToptotheSubTop.Theexactlocationofthepocketholesisnotcritical.Theimportantthingisthat
theydonotlineup
withthescrewholesinyourT-Track.Ifyoudonot
haveapocketholejig,theTopca
nbesecuredwithfinishingnailsorglue.
Top
Trim
&T-Tra
ck
Page6
8/13/2019 Workbench Preview
5/27
Attach the Panels to the BasePage 17
Copyright 2006by Robert E. Reedy, Vandalia, OhioC
18 1/4"
18 1/4"
29 1/4"
Lower Back Supports
8/13/2019 Workbench Preview
6/27
Copyright 2006 by Robert E. Reedy, Vandalia, OhioC
Attach theStiffener & Casters to the BasePage 18
Stiffen
er
Attach the casters to the base as shown. Then position the stiffener as closeto the front as possible while still allowing clearance for the swival casters
to rotate. Mark the position of the stiffener, thendrillabout six holes for #8wood screws through the base. Apply some glue and secure the stiffener tothe basewith2" #8 screws.
The screwheads will be inside cabinetbelow the drawers so it doesn'tmatter if you use flathead or pan headscrews..
8/13/2019 Workbench Preview
7/27
Attach
thebackt
othe
vertica
lpane
lsand
basew
ith1
1/2"#
8flath
eadscrew
sassho
wn.
Attach The BackPage 19
Copyright 2006by Robert E. Reedy, Vandalia, OhioC
8/13/2019 Workbench Preview
8/27
Attach the middle shelf to thesupports.
Attach the Middle ShelfPage 20
Copyright 2006 by Robert E. Reedy, Vandalia, OhioC
Middle
Shelf
8/13/2019 Workbench Preview
9/27
Assemble the FaceFramePage 21
Copyright 2006by Robert E. Reedy, Vandalia, OhioC
Assemblethe fronttrim pieces (face frame) as shown. Be sure the horizontaldrawer separatorpieces are properly spaced so theylineup withthe drawer
slides.
Thetop of eachpiece of horizontal drawer separator trimshouldbe flush withthe top of a drawer slide.
Pocket holes are the easiest waytojoin trim or face frames as theyare oftencalled. if you don't have a pocket hole jig, you can use dowel joints.
Don't forget! Thepocket holes go onthe back sideof the faceframe.
8/13/2019 Workbench Preview
10/27
Copyright 2006 by Robert E. Reedy, Vandalia, OhioC
Attach the FaceFrame to the CabinetPage 22
Attach the assembled faceframe tothe cabinet with finishing nails.Then, countersink and fill the nail
holes withwoodputty.
8/13/2019 Workbench Preview
11/27
When all the blocks are level, tighten the screws andrecheck that theydid not move.
Copyright 2006by Robert E. Reedy, Vandalia, OhioC
The important thing is that the top surfacesof the levelingblocksbe level witheachother. This will provide a flat surface tomount the sub top to.
Attach the LevelingBlocks to the End andCenter PanelsPage 23
Now, you are ready to attach the leveling blocks. This is the way you ensure that the top is perfectly flatwhen the workbench is completed. First, drillthree1/4"diameter holes completely through eachleveling
block, (the two shortest ones only need two holes). The exact location of the holes is notcritical. Drill ahole about 2" from each end and one in the middle of each leveling block. To keep the gluefromsetting
before you're finished, it's bestto attach the end and centerpanel levelingblocks firstand ensure theyare
level with each other before attaching the front and rear ones.
After all the blocks are in place, use astraight edgeto ensure the top surfaces of allthe leveling blocks are level with each other.If you haveafourfootlevel, that wouldwork great.
Apply some glueto the mating faces and attach the end and centerpanellevelingblocks using 1 1/2"#8 pan headscrews with flat washers asshown. Do not tighten the screws yet as the blocks must be leveled first.
8/13/2019 Workbench Preview
12/27
Copyright 2006 by Robert E. Reedy, Vandalia, OhioC
Attach the Front & Rear Leveling Blocks
Page 24
Apply glueto the mating surfaces and attach the front and rear levelingblocks as shown in the diagram.Use your straight edge to ensure the tops are even with the tops of the end and center leveling blocks.Thentighten the screws.
8/13/2019 Workbench Preview
13/27
Copyright 2006 by Robert E. Reedy, Vandalia, OhioC
Attach the SubTopwith1 1/2"#8flathead screws. TheSubTopshould
be flush to the edges of the cabineton all foursides.
Attach the SubTopto theCabinet
Page 25
8/13/2019 Workbench Preview
14/27
Copyright 2006 by Robert E. Reedy, Vandalia, OhioC
Attach the Inner SubTopTrimto the SubTop
with1 1/2"#8 flathead screws. Be surethe topof the trimis flushwith the top surface of theSubTop.
Attach the Inner Sub TopTrim
Page 26
8/13/2019 Workbench Preview
15/27
Attach the Middle Trim tothe Inner Sub Top Trim
Page 27
Copyright 2006 by Rober t E. Reedy, Vandalia, OhioC
Attach the Middle Sub Top Trim to the Inner Sub Top
Trim with 1 1/2" #8 flathead screws. Be sure to spacethese screws so they don't interfere with the screws inthe inner trim or the T-Track which willbe attched to theMiddle SubToptrim. Thepocket holes willbe used toattach the edges of the top to the trim.
8/13/2019 Workbench Preview
16/27
Attach the Topto the SubTop
Page28
Copyright 2006 by Rober t E. Reedy, Vandalia, OhioC
Pocket Hole Screws
Attach the Topto the SubTopwith1" #8 flathead screws through the cutouts for the T-Track. Secure theedges of the top withpocket holescrews through the holes youdrilled through the Inner SubTopTrim.Youcan secure the right sidewithscrews fromthe underside of the sub top.If youprefer, youcan gluethe Topto the SubTop. However, gluing it willmake it much more difficult to replace the top in the
future if youneedto.Note: The dimensionsgiven in theseplans arebased using T-Track that is 3/4" wide and 1/2"thick. If your T-Track is a different size, you willneed to modify the thickness of the inner trimaccordingly.
8/13/2019 Workbench Preview
17/27
Attach the T-Track & Miter track to the Top
Page29
Copyright 2006 by Rober t E. Reedy, Vandalia, OhioC
Top T-Track
Attach the Lower Track Support to the left sideof the cabinet with six 2" #8 flathead screws.Position this piece so it is 1" below the SubTopTrimand centered front to back.
Attach the T-Track to the top as shown with1" #6 screws. Some manufacturers countersinkthe holes formounting the track and others do not.Frommy experience, I prefer flathead screws withcountersunkholes. This keeps the screw heads from interfering with the bolts sliding through the track. The track I
used for the prototype was designed for pan head screws, so I countersunk them on my drill press.
8/13/2019 Workbench Preview
18/27
Attach the T-Track to theEdges of the Front and Ends
Page30
Copyright 2006 by Rober t E. Reedy, Vandalia, OhioC
Attach the edge T-Track on each end and along the front to the middle Sub Top Trim with 1" #6 screws.Position this T-Track under the bottom surface of the Top as shown in the detail drawing.
T-Trackjoins at the corners likethis so you can slide the bolts inand out. End T-Track
Front T-Track
EndT-Track
Detail
Attach the Lower T-Track to the Lower T-TrackSupport. The T-Track should be centered top to
bottom.
8/13/2019 Workbench Preview
19/27
Attach the Lower Front Trim to the Frontand Ends
Page31
Copyright 2006 by Rober t E. Reedy, Vandalia, OhioC
Detail
Attach the Lower TopTrimon eachend and along the front to the middle SubTopTrimwith1 1/2"finishing nails.
If you cut the top a little larger than the dimensionscalled for, you can trim it with your router and aflush trimmingbit. Usethe Lower TopTrimfor the bit bearing to follow.
TheLower TopTrimjoins atthe corners likethis.
Lower Trim
Attach the Lower Track Trimwithfinishingnails.
Lower Trim
8/13/2019 Workbench Preview
20/27
Step2 Step3
LeftSide
Step1
Right Side
Front
Back
Step5Step4
Support the drawerboxes with1/4"thick strips of wood andattach the drawer frontswith 1 1/8" screws as shown. This is necessarybecause the bottom of the front mustbe 1/4"below the bottom of the boxso it willoverlap the rearcabinet trimwheninstalled.
Apply a little glue to the mating surfaces andassemble the drawerboxes.
Assemblethe front, back, and right side with finishing nails as shown in Step 1.Insert the bottom as shown in Step 2. Attach the left side as shown in Step 3.
Assemble the DrawersPage 32
Copyright 2006by Robert E. Reedy, Vandalia, OhioC
8/13/2019 Workbench Preview
21/27
8/13/2019 Workbench Preview
22/27
Attach the Middle Door trim
Page34
Copyright 2006 by Robert E. Reedy, Vandalia, OhioC
Attach the Middle Door Lip to the back of either of the cabinetdoorsso half of it is visible as shown. Attach it to the backof the
door witha couple of 1" wood screws. Theleft door is notpictured in the drawing for clarity.
This piece serves as a door lip so there is no visible gap betweenthe doors.
Now, you're ready to attach the Drawer and Door handles and your workbench is finished.
8/13/2019 Workbench Preview
23/27
Assemble theEZ Mount StopPage 36
Copyright C 2006 by RobertE. Reedy, Vandalia, Ohio
Attach the Posts to the ends of the Stop Bar with pocket hole screws asshown below. Next, cut four 7/8" long dowel pins from 1/4" dowelrod. Apply some glueand insert a 1/4"dowelpin into eachholein theendsof the Posts. (Thedowelpinsshouldprotude about 3/8"fromtheends of the Posts.)
Place the Jawsoverthe protuding dowelpinsas shown above. (Do notgluethe dowelpinsto the Jawsas the Jaws mustbe allowed to pivotin order to work as clamps.) Insert a 5/16 carriage bolt through theholes as shown. (The carriage bolt should be 5" long. Secure the
pieces witha flat washer and knob.
8/13/2019 Workbench Preview
24/27
Clamping System UsagePage 37
Copyright C 2006 by RobertE. Reedy, Vandalia, Ohio
The T-Track clamping system provides a flexible way of clamping both large and smallwork pieces. Most work pieces can be clamped using the two Clamp Jaws and the RearStop. TheClamp Jaws are usedwiththe T-Track that runs along the front edge of the
workbench. TheRear Stopis usedwiththe T-Track thatis embedded in the top surface ofthe workbench.
Forlonger workpieces, youcanuse the the Clamp Jaws withthe T-Track on the ends of theworkbench. The EZ Mount Stop may be secured anywhere along the workbench top. Thesimple clamps on each end of the EZ Mount Stop grip the edge of the workbenchtop aswell as C-Clamps. This feature enables you to use the workbench as a large bar clamp forgluing up boards.
Youcanmake the clamping system gripthe workpiece even tighterby gluing strips of 100gritsandpaper along the edges thatcontactthe workpiece. Thesandpaperrequires muchlessforce thanthe surface of barewood.
The button arrangement on the Clamp Jaws allows you to filp the Clamp Jaws over forthicker work pieces. The drawings on the next two pages illustrates how the clamps work.
To clamp a work piece, position the workpieceso the edge protudes slightly over the edgeof the workbench top as shown. Then,position the Rear Stopagainst the workpiece andtighten it to T-Track using the knobs. Next, tighten the Clamp Jaws against the workpiecewiththe knobs and your work piece willbe clampedjustlikewitha vice.
Forthinner workpieces,position the Clamp Jaws andRear Stop as shown. If yourworkpieceis thinner than 3/4", you can place strips of wood under the work piece so it isslightly higher than the top edges of the Clamp Jaws.
For thicker workpieces, flip the Clamp Jaws so the second button is against the LowerT-Track Trimandreverse the Rear Stopso the thicker edge is against the workpiece.
8/13/2019 Workbench Preview
25/27
Using theClampsPage 38
Copyright C 2006 by RobertE. Reedy, Vandalia, Ohio
Rear Stop
T-Track
Second Button
Button
Clamp JawWorkpiece
For thicker workpieces, flip the Clamp Jaw so the second button is against the Lower T-Track Trim
and reverse the Rear Stopso the thicker edgeis against the workpiece.
T-Track
Button
Second Button
Clamp Jaw
Workpiece
Rear Stop
For thinner workpieces,position the Clamp Jaws and Rear Stopas shown.
8/13/2019 Workbench Preview
26/27
Clamping LongWorkpieces
Page 39
Copyright c by Robert E. Reedy, Vandalia, Ohio
To clamp longworkpieces, use theClamping Jaws and EZ Mount Stopasshown.
8/13/2019 Workbench Preview
27/27
Snapshots
Page 40
Clamping a large Work Piece Vertically
Clamping a Small Work Piece
Clampinga Large Work Piece
Clamping a Thick Work PieceClamping a Work Light