This project was built and designed by Zach from Bear Mountain Builds. It’s a midsize workbench designed specifically to support benchtop tools like a drill press, band saw, or jointer, offering a sturdy platform at just the right height for tasks that are too tall for a standard workbench.
Zach’s design strikes a smart balance between strength, function, and clean joinery. This is a practical shop project for any woodworker who needs to organize tools while improving workflow and comfort.
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Why Midsize Makes Sense
Benchtop tools can be awkward to place. Standard-height workbenches often sit too low once a tool is added, while putting them on the floor isn’t ideal either.
Zach’s midsize bench solves this by creating a comfortable, medium-height work surface that fits well into most shops. It’s also great for working on tall projects or assembly tasks where a standard bench isn’t the right fit.
A Solid Frame from 2x4s
The base of the workbench is built using common 2×4 lumber. Zach recommends shopping at the beginning of the week when lumber is freshly restocked to find the straightest boards.
For a cleaner appearance, the 2x4s are planed to remove the rounded edges before being cut to length on the miter saw. Pocket hole joinery is used throughout, offering reliable strength while keeping the build process efficient.
Lap Joint Leg Design
The legs are constructed with a lap joint design—one long leg and one short leg glued and screwed together. This keeps screw heads hidden and creates a cleaner look for shop furniture.
Zach uses corner clamps to maintain alignment during assembly and emphasizes checking pocket hole placement for consistent assembly later.
Building with Strong Joinery
The frame is assembled using lap joints and stretchers secured with pocket screws. These joints transfer weight directly down the legs for excellent load capacity.
Everything is checked for square as it’s built, with clamps helping hold pieces in place. Zach’s process shows how to keep things efficient without sacrificing accuracy.
Cutting and Installing Platforms
The top and bottom shelves are cut from ¾-inch plywood. Zach uses a foam pad on his assembly table to support full sheets during cutting, keeping them clean and safe from damage.
The bottom shelf requires notched corners to fit around the legs. Zach shares a clever method of sliding the shelf in at an angle before dropping it into place—a smart workaround for tight-fitting parts.
Drawer Sidewalls and Frame Corrections
The sidewalls for the drawers are cut from plywood and inset slightly to allow the drawer fronts to sit flush. During glue-up, Zach notices some minor unevenness caused by wood movement and corrects it by clamping the high points flat until the glue sets.
It’s a great reminder that even well-prepared material can shift and that making small corrections during the build can save bigger problems later.
Building and Assembling Drawers
Each drawer uses lap joints for strength and appearance. The sides cap the front and back, hiding end grain and producing a cleaner finished product.
Corner clamps make drawer assembly easier and more accurate. After glue and brad nails hold the boxes together, the bottoms are attached and squared to help the drawers glide smoothly once installed.
Simple and Accurate Drawer Slide Installation
Zach’s spacer method for installing drawer slides stands out as a highlight of the build. It requires no clamps or jigs—just a few shop-made spacers to ensure perfect placement and spacing.
Slides are installed using spacers between drawers, and the result is a clean, professional fit without frustration. Zach says this method has permanently replaced his older approach.
Attaching Drawer Fronts and Handles
The drawer fronts are inset for a modern, flush look. Spacers are used to maintain equal gaps around each front, and screws are driven in from the inside of the box to keep the exterior clean.
Drawer handles are added before closing off the back of the bench, making them easier to grab and adjust during alignment. Zach recommends using a simple measuring method for just a few drawers, but a jig would help for larger batches.
Final Details: Casters and Back Panels
The bench is finished off with large 4-inch casters, which Zach prefers over smaller wheels for easier movement on debris-covered floors. Pre-drilled holes and washers help secure the wheels in place with lag screws.
The back panel is cut from plywood and attached with screws only—no glue—so it can be removed for access or maintenance. Zach also seals the back to reduce dust buildup inside the drawers.
A Smart Addition to Any Workshop
This midsize bench is a functional, long-lasting upgrade to any woodworking shop. It’s purpose-built for organizing benchtop tools while remaining mobile and versatile.
With a clean frame, thoughtful drawer layout, and clever build strategies, Zach turns a basic workbench into a powerful part of the shop.
Get Zach’s plans here: https://www.bearmountainbuilds.com/products/benchtop-tool-workbench.