Rock Solid Workbench (Part 2 of 2)

Continuation of “Rock Solid Workbench (Part 1 of 2)”

Step 7 — The lower rail members consist of 2 x 4′s. And the members running between the front and back lower rail members consist of 2 x 4′s also. Construction of the lower rail members and associated parts is basically identical to the top rail members & associated parts, except that the wood consists of 2 x 4′s instead of 2 x 6′s.

A photo of the lower rail assembly is shown in the following photo.

Step 8 — After framing, the carriage is complete. The next step is to cut & install the workbench top. For the top I installed two sheets of 3/4″ OSB, thereby giving me a 1-1/2″ thick workbench top. The next three photos show the OSB sheets being positioned, clamped in place, and cut to length. I had Home Depot cut the OSB sheet into two 2 ft x 8 ft sheets. Much easier to handle this way, hate having to wrestle with 4 ft x 8 ft sheets.

Regarding the OSB sheets, the 3/4″ sheets were only available with tongue & groove type joints on the two 8 ft sides, at the Home Depot I frequent. I laid out the OSB sheets such that the tongue & groove joints were on the backside of the workbench. For me this was not a deal breaker, but you may feel otherwise. In which case there’s always the 3/4″ plywood option.

Pictured below in the next two photos are the tongue & groove joints laid out as discussed above.

Step 9 — In the photo below, 3/4″ OSB is shown fasten to the back of the workbench. Also shown is 3/4″ OSB fastened to the side (Typical for both ends) of the workbench. Both the back and side OSB shown is sandwiched between the top and bottom rails shown.

The back and side OSB sheets are fastened to the workbench legs with 3″ length deck screws. Later when the 3/4″ OSB shelving sheet (Below the workbench top) is installed, 1-1/2″ length brad nails (Spaced 6″ on-center) will be shot along the bottom side of the OSB sheet on the backside of the workbench, sandwiched between the top and bottom rails. The brads will be shot thru the back OSB sheet and into the OSB shelving sheet below the workbench top.

Step 10 — The following two photos show the 1 x 4 board which runs as shown between the two back legs. I fastened the 1 x 4 to the 2 x 6′s above it with three 2″ brad nails for each of the seven 2 x 6′s located above the 1 x 4.

The 1 x 4 functions as a backboard for fastening the top of the back OSB sheet to. I used 1-1/2″ length brad nails for fastening the top of the back OSB sheet to the 1 x 4 board. I shot the brad nails at 6″ on-center.

Step 11 — The following four photos show the 3/4″ OSB shelving below the workbench top. The first photo shows how I went about clamping the OSB down and use of a pipe clamp & scrap piece of wood to hold the OSB edge coplanar with the front face of the bottom rail.

This next photo shows how I butted the OSB shelving up against the legs. The open area between the front and back legs will be closed up later in this post.

And the next two photos are just general pictures showing the workbench taking shape.

Step 12— There’s a gap between the front and back legs as shown in the photo below.

To close up the gap shown in the photo above, I sized and cut a piece of 3/4″ OSB to close up the gap. I tipped the workbench up to install the OSB as shown in the following photo. OSB was installed at both ends of the workbench to close the gap shown in the photo above.

The closed up gap which I think of as a shallow well is shown before and after several hammers are deposited, in the following two photos.

Final Thoughts
The workbench built is not the most beautiful or elegant looking workbench on the block. But it is rock solid. I plan to use the same design for a 7 ft x 3 ft workbench. Plan to put the 7 ft x 3 ft workbench on the other side of my 8 ft x 16 ft addition.

If you enjoyed this post, I would be very grateful if you would share it by email with a friend, or on Google+, and/or Facebook. While I am being needy, would you give me a “Like” on my Facebook page (Woodworking with AJO)? My Facebook page “Like” button is on the right side of this page, or you can click on the link shown below for my Facebook page. Thanks a bunch.

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Until next time, take care

Update to This Post
Since posting  “Rock Solid Workbench,” a woodworker by the name of Joseph has built this workbench. Joseph made a few modifications to my design, and I like Joseph’s modifications.     I asked Joseph if he would send me Photos when he finished his workbench, and he has. Thanks for the photos Joseph, which are shown below.

























Here is what Joseph had to say about the modifications he made.

“You’ll notice some changes from your own bench: I made the bench a full 8ft, and moved the legs in a foot from each side. I also used a single sheet of plywood for the top, and covered in an easily-replaceable hardboard. I haven’t yet decided if I will cover the sides or back of the shelf, or make those clever bins between the legs. This bench is indeed rock-solid!”

Joseph, in closing thanks again for the photos and describing the modifications you made.