Looking for a versatile workbench that can adapt to your space? This modular workbench design is created by Bear Mountain Builds, and it’s perfect for any workshop, big or small.
Materials and Tools Needed
- Materials:
- 3/4-inch sanded plywood (1 sheet)
- 2×4 lumber (for the frame and legs)
- 4-inch heavy-duty casters
- Wood glue
- Construction wood screws
- Latch clamps
- Tools:
- Circular saw or table saw
- Planer (optional)
- Drill and drill bits
- Pocket hole jig
- Clamps (90-degree positioning clamps recommended)
- Measuring tape
- Carpenter square
Step 1: Cut the Plywood
Start by cutting a piece of 3/4-inch sanded plywood into four equal sections. Each piece should be approximately two feet by four feet, but this may vary depending on the original size of your sheet. Make sure the grain runs lengthwise.
Step 2: Build the Frame
Next, cut the 2x4s for the frame. If you have a planer, run them through to crisp them up, though this isn’t necessary. The frame will consist of legs and stretchers that create a sturdy structure.
Step 3: Assemble the Legs
The legs are made from a long and a short piece to form a lap joint. Apply wood glue to the short piece and position the long piece over it, using spacers to ensure the joints are even. Secure them with screws.
Step 4: Assemble the Side Frames
With the legs assembled, cut out the stretchers and begin putting together the side frames. Use clamps and a carpenter square to ensure everything is flush and square. Pre-drill holes to avoid splitting the wood.
Step 5: Drill Pocket Holes
Drill pocket holes in the cross pieces. This will allow you to attach the top and bottom sections securely. Consider making a measuring stick for consistent hole placement.
Step 6: Assemble the Cross Pieces
Using 90-degree clamps for easy assembly, attach the cross pieces to the side frames. Ensure everything remains square and tight during assembly.
Step 7: Attach the Casters
Once the frame is complete, attach the casters using lag screws. Position them carefully to avoid interference with pocket screws from the frame.
Step 8: Attach the Plywood Tops
Notch out the plywood for the bottom platform and secure the tops with pocket screws. This will provide a clean look while allowing for easy replacement later.
Step 9: Final Assembly and Adjustments
Check the square of your frame by measuring the diagonals. Adjust as necessary to ensure everything is aligned. Sand the tops and round the edges for a finished look.
Step 10: Connect the Workbenches
To make the workbench modular, install latch clamps on the insides of the legs. This allows you to connect or disconnect the two tables easily, creating a larger workspace when needed.
Final Thoughts
This modular workbench is not only practical but also a fun project for beginners and experienced woodworkers alike.