This project was built and designed by Nick Starrett.
It features a modular, mobile workbench that doubles as an outfeed table and includes a space-saving folding extension—ideal for small and medium-sized shops.
Nick’s goal was to create a tougher, more flexible workstation after years of working on a worn-out bench.
The result is a thoughtful two-piece bench system with heavy-duty legs, a durable top, and clever hardware that adds real shop value.
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A Smarter Approach to Workbench Design
Every shop needs a solid bench, but Nick didn’t want to simply copy a standard design. His new setup is built from two benches that can be used independently or joined together for larger tasks.
The entire system sits on casters for mobility, includes a fold-down extension for added surface area, and uses laminate-topped plywood for a clean, low-maintenance work surface.
Materials and Construction Strategy
Nick selected dense hardwood for the legs and high-quality plywood for the cabinet boxes and top. This combination offers weight, strength, and long-term stability without making the bench unnecessarily complex.
Rough hardwood was milled down using standard jointer and planer techniques.
Multiple boards were laminated together to form thick leg blanks, which were then flattened again for consistent geometry.
Building the Base and Legs
Once milled, the hardwood boards were glued up to form oversized blanks. After curing overnight, they were re-jointed and planed to final dimensions.
Glue selection played a role too—Nick used a formula that closely matched the hardwood’s tone so glue lines would stay subtle. Each leg was checked for squareness and finish-planed before any joinery was laid out.
Joinery That Adds Rigidity
To support the aprons and side panels, Nick used a rabbet technique instead of relying only on fasteners. A notch was cut into each leg using the jointer, creating a recessed channel where the plywood panels could be seated.
This approach locked the aprons into place, improved side-to-side rigidity, and created a stronger mechanical joint than simply screwing through end grain.
Assembly Tips That Save Headaches
Nick recommends assembling one side of the base at a time. Trying to glue and clamp all four sides at once often leads to frustration and misalignment.
Dry fitting the panels, aprons, and legs before applying glue gives you time to adjust any parts that are too tight or slightly oversized. A quick sanding pass or edge trim can make a big difference in how smoothly final assembly goes.
Shop-Grade Drawers and Casework
The drawer boxes and cabinet faces were built from plywood to keep the weight manageable while ensuring durability.
These components were built in tandem with the base so everything aligned properly as the structure came together.
Nick kept the drawer design flexible, suggesting that woodworkers size them to fit their own tools or shop habits. Durable fasteners and accurate cuts were the priority—not fancy joinery or hidden hardware.
Choosing a Tough Benchtop Surface
Bare plywood tops might be easy to build, but they don’t hold up well over time. For this bench, Nick applied a durable laminate to the surface using contact adhesive.
The laminate creates a smooth, easy-to-clean work surface that resists glue spills, abrasion, and wear.
Applying contact cement requires good ventilation and proper PPE due to the strong fumes, but the result is a shop surface that looks great and stays functional.
The Folding Extension: The “Twist”
The standout feature of this bench is the fold-down extension. Rather than using bulky hinges or removable parts, Nick installed quick-release shelf brackets that lock when open and fold flat when released.
This makes the extension ideal for occasional outfeed use or as extra assembly space. When not needed, it tucks away neatly and doesn’t interfere with mobility or storage.
Care was taken to position the brackets so they wouldn’t obstruct drawers or other internal hardware. The extension can be deployed quickly and holds steady under weight.
Mobility That Works
Heavy-duty casters were installed under every leg, allowing both bench sections to be repositioned with ease. The casters are rated for high loads and include locks for safety.
A mechanical latch was also added between the two benches to keep them securely joined when needed. This makes the workspace feel like one large unit without any shifting during use.
Storage That Stays Accessible
Nick added hooks and side storage options to keep tools like handsaws close by. This minimizes trips across the shop and keeps the benchtop free for larger projects.
Small upgrades like these make a noticeable difference in workflow. The bench becomes not just a place to work—but part of the way you work.
Final Setup and Flexibility
Once assembled, the two benches and folding extension gave Nick a massive, flexible workspace. The laminate surface makes cleanup fast, and the folding extension offers bonus space without permanently taking up floor area.
The modular design allows each bench to be used independently or locked together depending on the task. It’s a smart solution for shops that need to adapt to different types of work without building multiple specialized tables.
Please support Nick by visiting his website here: https://www.nickscustomwoodworks.com/.