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www.BobsPlans.com
Garage Workbench Plans
Every home woodworker knows the importance of making efficient use of the available space in his or her shop. This workbench is designed to provide the maximum functionality using the minimum amount of space possible. It provides a work surface of about six feet by two feet and is about 35 in height. Its just the right size to provide ample work space for most projects.
The features that make this workbench ideal for the home shop are the built in clamping system, the nine drawers, the center cabinet space, and the mobility. The four inch casters enable you to easily roll it into position when needed and roll it aside when it is not in use.
The top surface is made of two layers of 3/4 MDF. This provides an extremely flat and solid work surface. The T-track inlaid in the top and around the edges provides a versatile clamping system that easily clamps very small or very large work pieces.
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.
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
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
Materials List - 1
Qty Size Material Item name
2 29 1/4 by 19 3/4 Oak Plywood End Panels
2 28 1/4 by 18 1/4 3/4 Plywood Middle Panels
1 66 1/2 by 19 3/4 Plywood Base
1 66 1/2 by 28 1/4 3/4 Plywood Back
1 72 by 24 3/4 MDF Board Top
1 68 by 19 3/4 3/4 MDF Board Sub Top
2 69 1/2 by 1 1/2 3/4 Wood or Plywood 1st Front & Back Sub Top Trim
2 21 1/4 by 1 1/2 3/4 Wood or Plywood 1st End Sub Top Trim
2 71 by 1 1/2 3/4 Wood or Plywood 2nd Front & Back Sub Top Trim
2 22 3/4 by 1 1/2 3/4 Wood or Plywood 2nd End Sub Top Trim
2 36 1/2 by 3/4 T-Track Front T-Track
5 24 1/2 by 3/4 T-Track End & Top T-Track
1 72 by 3/4 by 1/2 1/2 Thick MDF or Wood Front Lower T-Track Trim
2 24 by 3/4 by 1/2 1/2 Thick MDF or Wood End Lower T-Track Trim
17 18 1/4 by 1 1/2 3/4 Wood Drawer Supports
5 6 by 1 1/2 3/4 Wood Small Drawer Supports
10 18 1/4 by 2 1/2 3/4 Wood Drawer Side Guides
4 18 1/4 by 3 3/4 Wood Lower Drawer Side Guides
6 18 1/4 by 2 3/4 Wood Lower Drawer Supports
2 14 1/2 by 2 3/4 Wood Lower Back Supports
1 27 1/2 by 2 3/4 Wood Center Lower Back Support
4 17 1/2 by 1 1/2 3/4 Wood 17 1/2 Leveling Block
4 16 3/4 by 1 1/2 3/4 Wood 16 3/4 Leveling Block
2 30 by 1 1/2 3/4 Wood 30 Leveling Block
1 66 1/2 2 by 4 (3 1/2 by 1 1/2) Stiffener
6 16 by 1 1/2 3/4 thick wood or plywood Drawer Trim
2 29 1/4 by 1 1/2 3/4 thick wood or plywood Vertical End Trim
x
Materials List - 2
Qty Size Material Item name
2 30 by 1 1/2 3/4 thick wood or plywood End Trim
2 23 1/4 by 1 1/2 3/4 thick wood or plywood Vertical Divider Trim
2 65 by 3 3/4 thick wood or plywood Upper & Lower Trim
1 3 1/2 by 30 1/2 3/4 thick wood or plywood Center Drawer Front
2 3 1/2 by 16 1/2 3/4 thick wood or plywood Top Drawer Front
2 4 1/2 by 16 1/2 3/4 thick wood or plywood 4 1/2 Drawer Front
2 5 1/4 by 16 1/2 3/4 thick wood or plywood 5 1/4 Drawer Front
2 7 by 16 1/2 3/4 thick wood or plywood 7 Drawer Front
2 19 by 14 3/4 3/4 thick wood or plywood Cabinet Doors
1 3/4 thick wood or plywood Door Lip
6 19 by 2 7/8 3/4 thick wood or plywood Top Drawer Sides
4 19 by 3 7/8 3/4 thick wood or plywood 3 7/8 Drawer Sides
4 19 by 4 7/8 3/4 thick wood or plywood 4 7/8 Drawer Sides
4 19 by 6 5/8 3/4 thick wood or plywood 6 5/8 Drawer Sides
2 28 3/8 by 2 7/8 3/4 thick wood or plywood Center Drawer Ends
4 14 3/8 by 2 7/8 3/4 thick wood or plywood Top Drawer Ends
4 14 3/8 by 3 7/8 3/4 thick wood or plywood 3 7/8 Drawer Ends
4 14 3/8 by 4 7/8 3/4 thick wood or plywood 4 7/8 Drawer Ends
4 14 3/8 by 6 5/8 3/4 thick wood or plywood 6 5/8 Drawer Ends
1 29 1/8 by 18 1/4 1/4 Hardboard Center Drawer Bottom
6 15 1/8 by 18 1/4 1/4 Hardboard Drawer Bottom
1 18 1/4 by 30 3/4 plywood Middle Shelf
xi
Rev 9/14/2010
3/4 "
MD
F or
ply
woo
d
C i /
66 1
/ 2"
Bac k
66 1
/ 2"
/
i
1 2 /
utout Draw ngs - Base Back
Bas
e
66 1
2"
xi
48"
96"
9" 8 1 4"
Cutout Drawings - Top
1st F
ront
& B
ack
Sub
Top
Trim
3/"
72"
3/
48"
96"
19 4"
68"
Sub
Top
24
Top
4 " M
DF
xiii
Mi
lls
M
il
lsd d
e Pa
n ed d
e Pa
n e
Dra
wer
Trim
(6)
Dra
wer
Trim
(6)
Dra
wer
Trim
(6)
Dra
wer
Trim
(6)
Cab
inet
Doo
rs ( 2
) D
raw
er T
rim (6
) D
raw
er T
rim (6
)
xiv
End
Pan
el
1st E
nd S
ub T
o p T
rim
1st E
nd S
ub T
o p T
rim
Ver
tical
End
Trim
(2)
End
Pan
el
30" L
evel
ing
Blo c
ks (2
) 2n
d E
nd S
ub T
o p T
rim
2nd
End
Sub
To p
Trim
30
" Lev
elin
g Bl
o cks
(2)
Ver
tical
End
Trim
(2)
2nd
F ron
t & B
ack
Sub
Top
Trim
2n
d F r
ont &
Bac
k S
ub T
op T
rim
Cab
inet
Doo
rs ( 2
)
(1)
Cen
ter D
raw
er F
ront
Mid
dle
Trim
(1) V
ertic
al D
ivid
er T
rim (2
)
Ver
tical
Div
ider
Trim
(2)
(1)
3/ l
Cen
ter L
ower
Bac
k Su
ppo r
ts
4" by 4' by 8' p ywood
Cutout Drawings - Panels
i(
i/
iia
lill
w)
66 1
/ 2"
Stf
fene
r M
ake
the
stffe
ner f
rom
1 1
2" th
ck m
a ter
-A 2
BY
4 w
ork
3/4"
thic
k m
ate r
ial
96"
Dra
we r
Sid
e G
uid e
s (1
0)
Dra
we r
Sid
e G
uid e
s (1
0)
Dra
we r
Sid
e G
uid e
s (1
0)
Dra
we r
Sid
e G
uid e
s (1
0)
Dra
we r
Sid
e G
uid e
s (1
0)
Dra
we r
Sid
e G
uid e
s (1
0)
Dra
we r
Sid
e G
uid e
s (1
0)
Dra
we r
Sid
e G
uid e
s (1
0)
Dra
we r
Sid
e G
uid e
s (1
0)
Dra
we r
Sid
e G
uid e
s (1
0)
(6)
(6)
(6)
(6)
(6)
Low
e r D
raw
er S
uppo
rts
Low
e r D
raw
er S
uppo
rts
Low
e r D
raw
er S
uppo
rts
Low
e r D
raw
er S
uppo
rts
Low
e r D
raw
er S
uppo
rts
3/4"
thic
k m
ate r
ial
67 1
/ 2"
Low
e r D
raw
er S
uppo
rts (6
) (6
)Lo
we r
Dra
wer
Sup
ports
Lo
we r
Bac
k S
uppo
rts (2
) Lo
we r
Bac
k S
uppo
rts (2
)
17 1
/ 2" L
evel
ing
Blo
cks
(4)
17 1
/ 2" L
evel
ing
Blo
cks
(4)
16 3
/ 4" L
evel
ing
Blo
cks
(3)
17 1
/ 2" L
evel
ing
Blo
cks
(4)
17 1
/ 2" L
evel
ing
Blo
cks
(4)
16 3
/ 4" L
evel
ing
Blo
cks
(3)
16 3
/ 4" L
evel
ing
Blo
cks
(3)
This
boa
rd s
houl
d pr
ovid
e en
ough
ext
ra w
o od
to m
a ke
the
par t s
for t
he c
lam
ping
sys
tem
.
Cutout Drawings - Misc
3 1/2" 7 1/2"7 1/2"
xv
End and Center Panels Page 1
2 /4"
/
Mi l ls
( i )
/
el
( i )
8 1
18 1 4"
dd e Pane
2 Requ red
29 1 4"
19"
End Pan
2 Requ red
The two end panels are 1" taller than the center panels. This is because the center panels sit on the top surface of the base and the end panels extend 1/4" below the bottom surface of the base..
The end panels are also 3/4" wider than the center panels. This is so they will be flush with the ends of the back section.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Base
Dim
ensi
o ns
& L
ayou
t
Pag
e 2
/
/
/
3/
2"3/
10"
9 1 /
4"
10"
9 1 /
4"9
1/4"
3/8"
18
" 2"
66 1
/2"
9 1 2"
9 1 2"
18 5
8"
19"
2" 2"
8"
8 "
9 1/
4"
5/8
Ba s
e
Cu t
the
bas e
fro m
3/4
" m
a ter
ial,
the n
dril
l and
cou
nter
sink
hol
es fo
r #8
scr e
ws
as sh
o wn
in
the
dra w
ing
abo v
e. A
ll th
e sc
r ew
s ar
o und
the
edg e
are
3/8
" fr
o m th
e ed
g e.
Cop
yrig
ht
C20
0 6 b
y R
o ber
t E. R
eedy
, Van
dalia
, Ohi
o
Back
Dim
ensi
o ns
& L
ayou
t
Pag
e 3
1/2"
3/4"
1/2"
/
3/
/
/4"
/
Bac
k
17
30
17
1 1 4" 4"
10"
17 1 8"
22"
28 1
66 1
2"
Cu t
the
bac k
fro m
3/4
" m
a ter
ial,
the n
dri l
l and
cou
nter
s ink
hol
es fo
r #8
scr e
ws a
s sho
wn
in
the
dra w
i ng
abo v
e.
Cop
yrig
ht
C20
0 6 b
y R
o ber
t E. R
eedy
, Van
dalia
, Ohi
o
Top Dimensions and Layout Page 4
2
7
F e 3/ n
2
T-Tr
ack
& M
iter S
lot C
utou
t Dim
ensi
ons
T- T
rack
Slo
t
Td
. t e s
s d t s
3/ // /
g
4"
2"
irst, cut the top from a piec of 4" MDF. The cut the
T-Track slots according to the drawing to the right.
4"
he T-Track slot dimensions are base on the center of the slots However, the exaclocation of thes item is strictly a matter of personal choice.
T-Track size vary from bran to brand. The mos common size are
4" wide by 1 2" deep or 3 4" wide by 3 8" deep. Cut the slots so the track you're usin is flush with the top surface.
24"
6"
Copyri Cght 2006 by Robert E. Reedy, Vandalia, Ohio
Sub Top Dimensions and Layout Page 5
Sub Top
68"
Dril
l and
cou
nter
scr
ewho
les
for #
8 fla
thea
d sc
rew
s in
the
loca
tions
sho
wn
belo
w.
1
/
/8"
/ 8"
/8"
l
le
/
/
1 /8"
1 /8"
10"
3"
3"
0"
3"
3"
3"
3"
1 1
8"
1 1
1 1
1 1
Sub
Top
Scr
ew H
oe
Layo
ut
Scre
w H
oLa
yout
19 3 8"
19 3 8"
4 5
4 5
/
1
9 1 2"
6"
26"
1
/
26"
6"
9 1 2"
19 3/4"
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Top
Trim
&T-
Tra c
k P
age
6
The
Sub
Top
tr im
is m
ade
o f 3
/4" t
hick
by
1 1/
2" h
igh
mat
e ria
l. T h
is b
e cau
se th
e T -
Trac
k is
1/2
" by
3 /4"
.
/rim
(i
)
1 1/
45
69 1
2"
45
1st F
ront
& B
ack
Su b
Top
T2
Req
ure
d
2"
45
45
im
ired
/im (
i)
1 1/ 1 1/
im (
id)
/
1 1/
r(
) 45
21 1
4"
1st E
nd S
ub T
op T
r2
Req
ure
d
2"
45
71"
2nd
Fron
t & B
ack
Sub
Top
Tr
2 R
equ
re
45
22 3
4"
2"
2nd
End
Su b
Top
T2
Req
u
45
2"
If y
ou h
ave
a po
c ket
hol
e jig
, I re
ccom
men
d dr
illin
g po
c ket
hol
e s in
the
2nd
Sub
Top
Trim
pie
c es a
s sho
wn.
The
se p
ocke
t hol
e s w
ill b
e us
ed to
secu
re th
e To
p to
the
Sub
Top .
The
exa
c t lo
catio
n of
the
poc k
et h
ole s
is n
ot c
riti c
al. T
he im
p orta
nt th
ing
is th
at th
ey d
o no
t lin
e up
w
ith th
e sc
rew
hol
e s in
yo u
r T-T
rack
. If y
ou d
o no
t hav
e a
poc k
et h
ole
jig, t
he T
op c
an b
e se
cure
d w
ith fi
nis h
ing
nail s
or g
lue .
Fron
t T-T
rack
(2 R
e qui
red)
En
d T-
Trac
k (2
Req
uire
d)
/2"
23 1
/4"
35 1
The
T-Tr
a ck
trim
is m
ade
o f 1
/2" t
hick
by
3/4"
hig
h m
ater
ial.
This
bec
a use
the
T-Tr
ack
is 1
/2" b
y 3/
4 ".
3/
im (
i)
4"
45
45
Fron
t T-T
rack
Tr
1 R
equ
red
72"
3//4
"
im (
ir)
4"
45
45
23 3
End
T-Tr
ack
Tr2
Req
ued
Cop
yrig
ht
C20
06 b
y R
ober
t E. R
e edy
, Van
dalia
, Ohi
o
Stiff
ener
(Mak
e th
e st
iffen
e r fr
om 1
1/2
" thi
ck m
ate r
ial)
66 1/2"
3 1/2"
Copyright C 2006 by Robert E. Reedy, Vandalia, Ohio
Drawer Slides / Stiffener / Misc Small Parts
18 1/4"1 1/2" Drawer Supports (20)
30"1 1/2" 30" Leveling Blocks (2)
Page 7
2 1/2"
18 1/4"
Drawer Side Guides (12)
18 1/4"
3" Lower Drawer Side Guides (4)
2"
18 1/4"
Lower Drawer Supports (6)
Lower Back Supports (2)2"
14 1/2"
Center Lower Back Supports (1)2"
28 1/2"
1 1/2"17 1/2"
17 1/2" Leveling Blocks (4)16 3/4"
1 1/2" 16 3/4" Leveling Blocks (4)
Rev 9/14/2010
Drawer Fronts, Front Trim, and Doors
Page 8
1 1/
/ i l im (2)D im (6)/29 1 4"
1 1 2" Vert ca End Trrawer Tr2" 16"
Mi l im (1)//
1 1/ i l Divid im (2)dd e Tr1 1 2" 30" 23 1 4"
2" Vert ca er Tr
im (2)Upper & Lower Tr
65"
3"
2" Middle Door Trim (1)
18 1/2"
Drawer Fronts Dimensions
30 1/2"
/
(1)
3 1 2"
Center Drawer Front
4 1/2" 3 1/2"
4 1/2 (2)" Drawer Fronts Top Drawer Fronts (2)
16 1/2" 16 1/2"
/
/ /4 (2)
16 1 2"
5 1 4" 5 1 " Drawer Fronts
19" i s (2)Cab net Door
7"
16 1/2" 14 3/4"
aw (2)7" Dr er Fronts
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Drawer Boxes Dimensions Page 9
Si (6)
2 7/
1
/ i (4)
1
/
Top Drawer des
8"
9"
3 7 8" Drawer S des
9"
3 7 8"
1/
3/
1/
il V
i
4"
8"
4"
Det
aew
-D
raw
er B
o tto
m C
utou
t
6 5/8" 4 7/8" / i (4)4 7 8" Drawer S des
6 5/8" Drawer Sides (4)
19" 19"
2 7/8" 2 7/8"
T (4)op Drawer Ends C (2)enter Drawer Ends
28 3/8" 14 3/8"
/ (4)6 5 8" Drawer Ends 3 7/8"
/ (4)4 7 8" Drawer Ends 3 7/8 (4)" Drawer Ends 6 5/8"
4 7/8"
14 3/8" 14 3/8" 14 3/8"
1/8"
(6) m (1)
/
1/8"
/
15
Drawer Bottoms Center Drawer Botto
18 1 4"
29
18 1 4"
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Middle Shelf Dimensions Page 10
/Middle lf
3
18 1 4" She
0"
/ L (2)
( t i / i ial.) 18"
2 3 4" ower Track Support
Lower Track Suppor s made of 1 1 2" th ck mater
Lower Track Trim (21" )
18"
(Lower Track Trim is made of 1/2" thick material.)
Copyright C 2006 by Robert E. Reedy, Vandalia, Ohio
Attach Drawer Slides Left Section - Left Panel Page 11
Copyright 2006 by Robert E. Reedy, Vandalia, Ohio
2 /4"
1
Left En
d Pane
l
4"
5"
6 3/4"
Drawer
Suppor
t
Drawer
Suppor
t
Lower D
rawer S
upport
Drawer
Suppor
t
Drawer
Side G
uide
Drawer
Suppor
t
Levelin
g Block
Lower D
rawer S
ideGui
de
Drawer
Side G
uide
Drawer
Side G
uide
1 /2"
5"
17"
5 1
9"
3"
1"
0 1
C
li i i el
/
/
3"
1 /4"
Drawer Support
Drawer Support
Drawer Support
Lower Drawer Support
Drawer Support
Lower Drawer Side Guide
Drawer Side Guide
Drawer Side Guide
Drawer Side Guide
i li io
Page 12 Attach Drawer S des Left Sect on - R ght Pan
5"
10 1 2"
17"
25 1 4"
8 1
Copyr ght 2006 by Robert E. Reedy, Vanda a, OhC
Attach Drawer Slides Center Section - Left Panel Page 13
3"
Drawer
Suppor
t
Drawer
Suppor
t
Levelin
g Block
Lower D
rawer S
upport
6 1/4"
11"
6"
13 3/4"
26 1/4"
Left Inside Panel
Copyright C 2006 by Robert E. Reedy, Vandalia, Ohio
Attach Drawer Slides Center Section - Right Panel Page 14
Drawer Support
Drawer Support
Leveling Block
Lower Drawer Supportl
6"
13 3/4"
26 1/4"
Right Inside Pane
Copyright C 2006 by Robert E. Reedy, Vandalia, Ohio
Attach Drawer Slides - Right Section - Left PanelPage 15
1 /2"
1
2 /4"
/
Drawer
Suppor
t
Drawer
Suppor
t
Drawer
Suppor
t
Lower D
rawer S
upport
Drawer
Suppor
t
Lower D
rawer S
ideGui
de
Drawer
Side G
uide
Drawer
Side G
uide
Drawer
Side G
uide
5"
0 1
7"
5 1
3"
18 1 4"
Copyright C 2006 by Robert E. Reedy, Vandalia, Ohio
Page 16 Attach Drawer Slides Right Section - Right Panel
Copyright 2006 by Robert E. Reedy, Vandalia, Ohio
5"
/
3"
/
Drawer Support
Drawer Support
Lower Drawer Support
Drawer Support
Drawer Side Guide
Drawer Support
Leveling Block
Lower Drawer Side Guide
Drawer Side Guide
Drawer Side Guide /
Right Section - Right Panel
17"
25 1 4"
19"
4"
5"
6 3 4"
1"
10 1 2"
C
Attach the Panels to the Base Page 17
1 /4"
/
2 /4"
L
8 1
18 1 4"
9 1
ower Back Supports
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach theStiffener & Casters to the BasePage 18
Attach the casters to the base as shown. Then position the stiffener as close to the front as possible while still allowing clearance for the swival casters to rotate. Mark the position of the stiffener, then drill about six holes for #8
Stiffen
er
wood screws through the base. Apply some glue and secure the stiffener to the base with 2" #8 screws.
The screw heads will be inside cabinet below the drawers so it doesn't matter if you use flathead or pan head screws..
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach The Back Page 19
Attach t
he back
to the v
ertical
panels
and bas
e with 1
1/2" #8
flathea
d screw
s as sho
wn.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the Middle Shelf Page 20
Middle
Shelf
Attach the middle shelf to the supports.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Assemble the Face FramePage 21
Copyright 2006 by Robert E. Reedy, Vandalia, OhioC
Assemble the front trim pieces (face frame) as shown. The dimensions for the drawer trim spacing are shown in the drawing above. The important thing is that the drawer trim pieces line up with the drawer slides.
If the drawer slides are off a little, position the drawer trim pieces so they are flush with the top of the drawer slides.
Pocket holes are the easiest way to join trim or face frames as they are often called. if you don't have a pocket hole jig, you can use dowel joints.
Don't forget! The pocket holes go on the back side of the face frame.
Lower Trim
Upper Trim
6 3/4"
3"
4"
5"
6 3/4"
3"
4"
5"
3"
Rev 9-14-2010
Attach the FaceFrame to the Cabinet Page 22
k s d
Attach the assembled face frame to the cabinet with finishing nails. Then, countersin and fill the nail hole with woo putty.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the Leveling Blocks to the End and Center Panels Page 23
Now, you are ready to attach the leveling blocks. This is the way you ensure that the top is perfectly flat when the workbench is completed. First, drill three 1/4" diameter holes completely through each leveling block, (the two shortest ones only need two holes). The exact location of the holes is not critical. Drill a hole about 2" from each end and one in the middle of each leveling block. To keep the glue from setting before you're finished, it's best to attach the end and center panel leveling blocks first and ensure they are level with each other before attaching the front and rear ones.
k
e s h l g /
t .
When all the blocks are level, tighten the screws and recheck that they did not move.
The important thing is that the top surfaces of the leveling blocks be level with each other. This will provide a flat surface to mount the sub top to.
After all the blocks are in place, use a straight edge to ensure the top surfaces of all the leveling bloc s are level with each other. If you have a four foot level, that would work great.
Apply som glue to the mating face and attac the end and center paneleveling blocks usin 1 1 2" #8 pan head screws with flat washers as shown. Do not tighten the screws yet as the blocks mus be leveled first
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the Front & Rear Leveling Blocks Page 24
Apply glue to the mating surfaces and attach the front and rear leveling blocks 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. Then tighten the screws.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the Sub Top to the CabinetPage 25
A /
h
ttach the Sub Top with 1 1 2" #8 flathead screws. The Sub Top should be flus to the edges of the cabinet on all four sides.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the Inner Sub Top TrimPage 26
/Attach the Inner Sub Top Trim to the Sub Top with 1 1 2" #8 flathead screws. Be sure the top of the trim is flush with the top surface of the Sub Top.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the Middle Trim to the Inner Sub Top TrimPage 27
Attach the Middle Sub Top Trim to the Inner Sub Top Trim with 1 1/2" #8 flathead screws. Be sure to space
e r b
. s
thes screws so they don't interfere with the screws in the inne trim or the T-Track which will e attched to the Middle Sub Top trim The pocket hole will be used to attach the edges of the top to the trim.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the Top to the Sub Top Page 28
Attach the Top to the Sub Top with 1" #8 flathead screws through the cutouts for the T-Track. Secure the edges of the top with pocket hole screws through the holes you drilled through the Inner Sub Top Trim. You can secure the right side with screws from the underside of the sub top. If you prefer, you can glue the Top to the Sub Top. However, gluing it will make it much more difficult to replace the top in the future if you need to.
P l
n e s d g a / e /
r , r
.
ocket Ho e Screws
Note: The dimensions give in thes plan are base usin T-Track th t is 3 4" wid and 1 2" thick. If you T-Track is a different size you will need to modify the thickness of the inne trim accordingly
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the T-Track & Miter track to the Top Page 29
Attach the T-Track to the top as shown with 1" #6 screws. Some manufacturers countersink the holes formounting the track and others do not. From my experience, I prefer flathead screws with countersunkholes. This keeps the screw heads from interfering with the bolts sliding through the track. The track Iused for the prototype was designed for pan head screws, so I countersunk them on my drill press.
T
e w t .
op T-Track
Attach the Lower Track Support to the left side of the cabinet with six 2" #8 flathead screws. Position this piec so it is 1" belo the Sub Top Trim and centered fron to back
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the T-Track to the Edges of the Front and Ends Page 30
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-Track joins at the corners like
i li ioC
s
F
D ail
Copyr ght 2006 by Robert E. Reedy, Vanda a, Oh
this so you can slide the bolt in and out. End T-Track
ront T-Track
End T-Track
et
Attach the Lower T-Track to the Lower T-Track Support. The T-Track should be centered top to bottom.
Attach the Lower Front Trim to the Front and Ends Page 31
Attach the Lower Top Trim on each end and along the front to the middle Sub Top Trim with 1 1/2" finishing nails.
If you cut the top a little larger than the dimensions called for, you can trim it with your router and a flush trimming bit. Use the Lower Top Trim for the bit bearing to follow.
The Lower Top Trim joins at
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il
im
L im
Copyr ght 2006 by Robert E. Reedy, Vanda a, Oh
Deta
the corners like this.
Lower Tr
Attach the Lower Track Trim with finishing nails.
ower Tr
Assemble the Drawers Page 32
Apply a little glue to the mating surfaces and assemble the drawer boxes.
Left Side
Ri i
t
k
ght S de
Fron
Bac
Step 1 Step 2 Step 3
Assemble the 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.
Step 4 Step 5
Support the drawer boxes with 1/4" thick strips of wood and attach the drawer fronts with 1 1/8" screws as shown. This is necessary because the bottom of the front must be 1/4" below the bottom of the box so it will overlap the rear cabinet trim when installed.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the Cabinet Doors Page 33
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n
Attach the cabinet doors so the tops alig with the tops of the drawers and the side alig with the ends of the middle drawer as show above.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Attach the Middle Door trim Page 34
nAttach the Middle Door Lip to the back of either of the cabinet doors so half of it is visible as show . Attach it to the back of the door with a couple of 1" wood screws. The left door is not pictured in the drawing for clarity.
This piece serves as a door lip so there is no visible gap between the doors.
Now, you're ready to attach the Drawer and Door handles and your work bench is finished.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Clamping System Parts Page 35
3/8" Button Hole
3/
"/4
5/ l le
"/2
2 3
16" Bo t Ho
3 1
"2
le8" Button Ho
/
Cl s (2)2"
4 1 2"
amp Jaw
Clamp Jaw Layout (Side 1) Clamp Jaw Layout (Side 2)
5/
/
/
/ i
3" 3"/R
Di 5/
2
8"
3 1 2"
1 1 2"
2 3 4"
End
Vew
1 1 2" ear Stop
a - 16"
4"
Di 5/
//
"
la - 16"
1 3 4" 1 3 4" 2"
28
EZ C amp Stop
P (2)ost (2)Jaws
Drill two pocket holes in each Post as shown below. Next, drill two 1/4" diameter holes in the end of each Post as shown. (The 1/4" holes
2" 2" should only be 12 1/2" 4"
/ )2" deep.
1/2"
Drill a 5/16" bolt through each jaw as
Di / 1/
ws
"/4
a - 5 16" 2"
Ja
2 13/8"
shown. Next, drill two 5/16" holes for the dowel pins in each Jaw as shown. (The dowel pin holes are 5/16" diameter so the
should be 1/2" deep.) Posts
sJaws can pivot over the pins. These hole
Copyright C 2006 by Robert E. Reedy, Vandalia, Ohio
Assemble the EZ Mount StopPage 36
a s s n / /
/( /)
(
r ) /h s ( .
.
Att ch the Post to the ends of the Stop Bar with pocket hole screw as show below. Next, cut four 7 8" long dowel pins from 1 4" dowel rod. Apply some glue and insert a 1 4" dowel pin into each hole in the ends of the Posts. The dowel pins should protude about 3 8" from the ends of the Posts.
Place the Jaws over the protuding dowel pins as shown above. Do not glue the dowel pins to the Jaws as the Jaws must be allowed to pivot in orde to work as clamps. Insert a 5 16 carriage bolt through the
ole as shown. The carriage bolt should be 5" long Secure the pieces with a flat washer and knob
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Clamping System Usage Page 37
The T-Track clamping system provides a flexible way of clamping both large and small work pieces. Most work pieces can be clamped using the two Clamp Jaws and the Rear Stop. The Clamp Jaws are used with the T-Track that runs along the front edge of the workbench. The Rear Stop is used with the T-Track that is embedded in the top surface of the workbench.
For longer workpieces, you can use the the Clamp Jaws with the T-Track on the ends of the workbench. The EZ Mount Stop may be secured anywhere along the workbench top. The simple clamps on each end of the EZ Mount Stop grip the edge of the workbench top as well as C-Clamps. This feature enables you to use the workbench as a large bar clamp for gluing up boards.
You can make the clamping system grip the work piece even tighter by gluing strips of 100 grit sandpaper along the edges that contact the workpiece. The sandpaper requires much less force than the surface of bare wood.
The button arrangement on the Clamp Jaws allows you to filp the Clamp Jaws over for thicker work pieces. The drawings on the next two pages illustrates how the clamps work.
To clamp a work piece, position the workpiece so the edge protudes slightly over the edge of the workbench top as shown. Then, position the Rear Stop against the workpiece and tighten it to T-Track using the knobs. Next, tighten the Clamp Jaws against the workpiece with the knobs and your work piece will be clamped just like with a vice.
For thinner workpieces, position the Clamp Jaws and Rear Stop as shown. If your workpiece is thinner than 3/4", you can place strips of wood under the work piece so it is slightly higher than the top edges of the Clamp Jaws.
For thicker workpieces, flip the Clamp Jaws so the second button is against the Lower T-Track Trim and reverse the Rear Stop so the thicker edge is against the workpiece.
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Using the Clamps Page 38
For thinner workpieces, position the Clamp Jaws and Rear Stop as shown.
T
B n
Cli
-Track
utto
Second Button
amp Jaw Workp ece
Rear Stop
For thicker workpieces, flip the Clamp Jaw so the second button is against the Lower T-Track Trim and reverse the Rear Stop so the thicker edge is against the workpiece.
S
ClkpiRear Stop
T-Track
econd Button
Button
amp Jaw Wor ece
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Clamping Long WorkpiecesPage 39
i c li hio
T p k
Copyr ght by Robert E. Reedy, Vanda a, O
o clam long wor pieces, use the Clamping Jaws and EZ Mount Stop as shown.
Snapshots Page 40
Clamping a Small Work Piece
Clamping a large Work Piece Vertically
Clamping a Large Work Piece
Clamping a Work Light Clamping a Thick Work Piece
c by Robert E. Reedy, Vandalia, OhioCopyright
Front ViewPage 1
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
Low
er T
rim
Upp
er T
rim
68"72"
End ViewPage 1
C 2006 by Robert E. Reedy, Vandalia, OhioCopyright
19"
End View
23 1/4"
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