A workbench is a much-needed tool for any workshop. But, many people think it costs a hand a leg to make the standard 2x4 workbench. A DIY workbench can be functional as well as lucrative if it is beautifully handcrafted.
Building a workbench at home requires no hefty tools except some common tools such as a table saw, clamp, etc. Also, the cost of the materials won't exceed $100 to make an ambitious and useful workbench. So, follow the below instructions and make your DIY 2x4 workbench.
The Easiest way to build a Workbench
A workbench requires no expensive materials. In fact, you can make a simple but stable workbench under $100. Also, it takes an afternoon to build your workbench without hiring a carpenter. So, collect the following materials and tools to build your classy style workbench.
- Four 33-in. 2x4s (legs A)
- Four 46-in. 2x4s (long stretchers B)
- Four 16-1/2 in. 2x4s (end stretchers C)
- Fifteen 5-ft. 2x4s (woodwork bench top D)
- Sixteen 3-in. x 3/8-in. lag screws
- Sixteen 3-1/2 in. x 3/8-in. Carriage bolts,
- Sixteen 3-1/2 in. x 3/8-in. nuts and washers
- 2 lbs. of 3-in. deck screws
- Measuring tape
- Speed square
- Clamps (more the better)
- Circular saw
- Table saw
- Hand Plane
- Belt/disk sander
Steps to build the DIY workbench
When you have collected all the required materials and the tools, now it's time to build a DIY workbench. SO, follow the steps described below:
Build the base first
At first, determine all the dimensions you need to build your design. Here, exact measurement is essential as the base legs are extended through the table top. For example, if table top is 24-inch wide, you must place 2 boards in from each side for 3-inch and 6-inch from both ends. So, each base will have at least 18-inch wide at the outer edge.
Now, make all the dadoes in the base legs. You can use a crosscut sled in the legs which help for stable support. Make sure that each leg has a dado of 3-inch wide and ¾-inch deep. Then make 2 dadoes for cross supports from which one is 7-inch from the bottom, and the other is 9.5-inch from the top.
Then make another dado from 3-inch from top of the leg for tabletop support. This dado ensures stability when you pound the top on the ground (if it is necessary).
When you have done everything off the table legs, now it's time to assemble the whole parts.
Make the top
Once you have completed everything for the base, now it's time to turn for making the top of the table. So, rip all the lumber so that you have a dimension of 1.5x3-inch finally. You can make it quickly by setting the fence to 3.25-inch inside the kerf. When one side is completed, rip the other side. Rip all the sides at 3-inch for a beautiful and square top on the table.
Then position all the lumbers and clamp on a guide fence to cross-cut all of them with a circular saw. Make sure that, each board has at least 1-inch added to the overall length. The extra length will be cut off later for the perfection.
Now, make a cubby hole to dado out 6-10 inches anywhere for ½ inch deep. Measure it several times to make sure as it is critical to assemble the top. Then cut it once. It helps to organize the boards. However, once you make the hole, glue up the two sections separately and then join them together. Here, you have to screw in a 2.5-inch wood screw into the boards for holding power. So, screw in at least 5 screws per board to make the joining strength. Otherwise, clamping won't be stable.
When the two boards are completed to be screwed in, now it’s time to join them for final thickness. Use the hand plane and the belt sander to square up the two halves. Now join the halves to get a stable and nice flat table top. Then cut the extra length you kept at the first step.
Assemble the entire workbench
Once the top and the base are completed, you have reached the final step of making the workbench. SO, before joining the two separate parts, loosen the bolts and the screws of the bases to create a space. Now, align the top to the legs and tap the top by a clamp into the place with a hammer. You can also use scrap wood to level the tabletop to the leg posts. When all the leg posts are aligned to the tabletop, tighten the screws and the bolts slowly.
You are done. Now, use some oil to refinish the top for years of use without needing to strip at all.