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Workbench Plans Free Preview

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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.
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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


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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


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


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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


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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..


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Attach

thebackt

othe

vertica

lpane

lsand

basew

ith1

1/2"#

8flath

eadscrew

sassho

wn.

Attach The BackPage 19



8/27

Attach the middle shelf to thesupports.

Attach the Middle ShelfPage 20


Middle

Shelf


9/27

Assemble the FaceFramePage 21


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.


10/27


Attach the FaceFrame to the CabinetPage 22

Attach the assembled faceframe tothe cabinet with finishing nails.Then, countersink and fill the nail

holes withwoodputty.


11/27

When all the blocks are level, tighten the screws andrecheck that theydid not move.


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.


12/27


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.


13/27


Attach the SubTopwith1 1/2"#8flathead screws. TheSubTopshould

be flush to the edges of the cabineton all foursides.

Attach the SubTopto theCabinet

Page 25


14/27


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


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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.


16/27

Attach the Topto the SubTop

Page28


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.


17/27

Attach the T-Track & Miter track to the Top

Page29


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.


18/27

Attach the T-Track to theEdges of the Front and Ends

Page30


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.


19/27

Attach the Lower Front Trim to the Frontand Ends

Page31


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


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



21/27


22/27

Attach the Middle Door trim

Page34


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.


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.


24/27

Clamping System UsagePage 37


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.


25/27

Using theClampsPage 38


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.


26/27

Clamping LongWorkpieces

Page 39

Copyright c by Robert E. Reedy, Vandalia, Ohio

To clamp longworkpieces, use theClamping Jaws and EZ Mount Stopasshown.


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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

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