SpaceCare Flip-up Casters
700-Pound Capacity, screw-on
TOP PICK: EAGLE CLAW
IN THIS GUIDE:
I had to part with an oversized workbench a few years ago to make room for other tools.
With 8″ steel casters, a 40″ height for easy sanding cubbies for tool storage, and a large 30×96″ top, I made many cabinets and projects on it. And while I’ve replaced its storage and downsized my projects, I’d still like to have it back some weekends.
But, sometimes, room in your workshop is more important, and a compact bench takes priority.
So, in this article, I’ll share a few tips and tricks on what to consider including in your workbench:
- Finding plans for a workbench
- Tools you’ll need
- Choosing between casters or a fixed workbench
- Shelving, cubbies, and drawers
- Integrating tools like your table saw or miter saw
- Choosing wood for the frame and top
- And construction tips
Page Contents
Find Your Plans
It’s tempting to jump in and start cutting; the best solution is to find a set of plans. But where best to look? Well, there are thousands of places to look for, but these are some of the top options:
Tools and Supplies for a Workbench
Basic Tools to Make a DIY Workbench
- Table saw or circular saw
- Miter saw
- Cordless drill
- Orbital sander
- Tape measure
- Pocket hole jig and screws
Supplies to Consider
Making a workbench is like cutting trim: you only get one shot to make it work.
And while a weekend-sized workbench won’t have all the complexity of a larger, drawer-filled bench, there are a few must-haves to include:
- 2×4’s or 4×4’s for legs
- Plywood for construction
- Basic drawers with ball bearing or soft close drawer slides
- Pegboard for the wall or back
Finding Plans for a Workbench
While building a workbench on the weekend is doable for almost skill levels, the level of complexity and need for workbench plans will vary based on the following:
- Fixed or mobile as a mobile workbench adds complexity, structural rigidity, and a longer build time
- Workbench size will determine the cost and time to assemble, sand, and install extras.
- Accessories such as fitting additional parts bins, tool storage, and shelving take time.
- Doors and drawers will add more time and cost and increase build complexity
Choosing a Workbench Design
If woodworkers disagree on anything, it’s how to build a bench best.
But, like fortunately, there are commonalities across most benches that show we all want a few basic needs filled, like a solid top, good storage, and a functional design for our projects.
So, here are a few places to check out plans (just be sure to come back):
- Family Handyman has an excellent browsable list of simple workbenches to get ideas on where to start.
- Woodsmith features a great selection of workbench plans for purchase
- And finally, Bob Vila has a few weekend-friendly workbenches
Workbench Design Considerations
Before getting too attached to your bench plans, you’ll want to consider the space it will go into. And projects, you may need the bench to support storage needs, bench height, mobility, budget, and the right tools to build it.
Planning Your Workbench Size
If there is any decision you might agonize over most, it’ll be the size of the workbench.
Too big, and it’ll eventually get in the way of other tools (or cars).
But make it too small, and you’ll wish you had more room.
What do you think is the best way to decide? Chances are your weekend workbench is less than 2 feet by 6 feet in size, or you’d be looking larger. So, place all your floor-based tools where they need to be, mark off your bench area, and leave room for future expansion.
Plan a Height HIgher than 36"
Most workbenches are higher than the standard kitchen countertops (36″). Depending on your height, a taller workbench has advantages in reducing strain or stooping.
While at 6′ 3″, I prefer a 40″ working height, grab a sander and hold it before you. Where is a natural position? Most benches are 38-42″ in height, but choose what’s comfortable.
Lastly, and perhaps most important, remember to factor in casters and the thickness of your top.
Mobilizing Your Weekend Projects - and Bench
Depending on the style of your bench, a set of heavy-duty casters is a must to allow your workbench to pull away from the wall and access all four sides.
So when should you go with a mobile bench? Consider:
- Flat top benches intended to make or sand projects that you’ll want to pull away from a wall
- Built-in tools such as a table saw where moving the bench for plywood clearance is a must
- Small workshops where benches will need to be moved and stored
Best Casters for a Workbench
Casters are not a one-size-fits-all solution for a workbench.
So how do you decide? As you probably know, casters can be expensive when you move past a compact 3″ tall caster.
A few things you’ll need to have:
- Locks on at least two of the casters
- Plan casters (and bench supports) every four feet for smaller casters.
- For larger, heavy construction benches, a metal caster will carry the load without the risk of creating a flat spot
Recommendations:
- Best compact casters: Non-marking Polyurethane casters for most small benches
- Metal heavy duty casters: Steel casters for heavy benches
Buying Material for Your DIY Weekend Workbench
Fortunately, there are only a few choices on a weekend workbench regarding basic construction.
First, you’ll need a collection of 2x4s that will match your plans.
Then you’ll need to make a few decisions:
- For the legs I prefer to use a 4×4 (3-1/2 x 3-1/2″ finished) as they are sturdier. And, if you use casters, offer the best mounting surface.
- Then, you can choose MDF or plywood for shelving within the bench. But, MDF is NOT sturdy when laid flat and will sag. Tip: use 3/4″ plywood.
- Lastly, you’ll want to consider a basic 3/4″ plywood top for the benchtop. Or, if you are doing a lot of woodwork, a thicker, banded wood top will offer the best benchtop.
Plywood vs. Flat Lumber vs. Thick Lumber Top
So you’re debating a plywood top (easiest, cheapest) vs. a wood top.
Or, you haven’t thought about it and want to know what’s possible in a DIY weekend workbench.
Here are a few considerations for choosing a top:
Plywood tops – work great for almost any project. Laminating a low-grade 1/2″ plywood with an MDF top is a cheap, very sturdy option. Wrap it in a 1×3″ for a finished look.
Flat-edge wood tops – for a simple look on a bench that will mostly hold stuff, this design is easy to build and doesn’t require the bulk of carrying a 4×8′ sheet (great for bench building without a truck).
Solid wood tops – beyond most weekend workbenches, if you want a lifetime benchtop and plan a complex bench, a solid wood top (think 3″ thick) is the ultimate one.
Choosing a Bench For Your DIY Weekend WOrkBench
It’s tough to find a woodworking vise that doesn’t get in the way.
I know, you’re probably thinking this is something you can skip.
But, for most workbenches, a vise will add extra capability for:
- Holding anything from wood to metal for sawing
- Sharpening mower blades
- Assisting during the assembly of projects
Metal Vises
Metal vises are best for general-use workbenches and, as the name implies, have metal jaws that offer a high clamping pressure.
But, more delicate woodworking projects may damage the wood surface. Here are a few things to consider when purchasing a vise like this:
- Jaw opening width
- Depth of throat (from screw to top, vertical)
- Base size and hole requirements
And, for a quick weekend project, these are simple additions to your bench.
Woodworking Vises for a Workbench
While this vise might be on the advanced side of building a bench on the weekend, this vise is perfect for woodworking projects.
As you can see, its wood design won’t damage wood projects. And, rather than mount on top of your bench, it fits into the side of your bench and doesn’t interfere with the bench top.
DIY Workbench with Pegboard
Perhaps you’re of an age where pegboard brings back memories of tan or painted messes on your parents or grandparents’ garage walls.
But those are no longer the norm in the pegboard. Dozens of ready-made pegboard organizers are modular, easy to install, and come in various colors.
And a DIY weekend workbench can be assembled in minutes to finish the bench area with pre-made storage.
Workbench Construction Tips and Tricks
To wrap up, a workbench is a project that almost any DIY’er can tackle.
But, there are some basic steps and safety considerations (and if saws aren’t in your skill, then maybe find another project):
- Follow all safety precautions of your tools. Still, trying to figure it out? You can buy a workbench instead.
- Control dust and wear a respirator, hearing protection, and safety glasses.
- Follow a plan if you haven’t built a structure before.
- Use lag bolts for securing the bottom frame for maximum stability
- And glue will make all parts that need to stay in place stay in place (when paired with screws).
- Plan for drawers vs. hurrying and skipping them. And ball-bearing drawer slides will make your DIY weekend workbench more usable.
Ready to Assemble Workbench
Still trying to figure out your skills are up to building the legs – but want a semi-custom workbench? Well, you’re not alone. And kits that will take the most challenging leg-building tasks are available.
Workbench and Shelving System
With this kit, forget a DIY weekend workbench and build a bench in the afternoon. Insert 2x4s, plywood, or MDF of your choice, and you’ll have a bench in just minutes.
Ready to Assemble Workbench
Do you want to skip the trip to the lumber yard and have a bench shipped to you?
It’s not a bad option, and a bench like the Olympia Tools workbench offers a ready-to-ship solution. Just unpack, assemble, and use.
Frequently Asked Questions
Can you put casters on a bench?
Two types of casters can be attached to a bench. The traditional method is to install casters under the leg posts and use brakes to prevent the workbench from moving. An alternate approach is a foot pedal-activated caster that can be lowered and raised, allowing the leg posts to sit directly on the floor.
What are the best drawer slides for a work bench?
The best drawer slides for a workbench are side mount drawer slides. Since side mount slides typically carry 100 pounds of weight, these slides will hold heavy loads of tools, sockets, and other supplies.
Do you have to screw a vise to the bench?
Both permanent-mount vises and clamp-on vises are available for benches.
Summary
To conclude, while a DIY weekend workbench is a fast project, remember you’ll likely use it for years or decades. So, complete all the essential add-ons like pegboard, drawers, and casters if they will improve usability.
- About the Author
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Eric has been a professional woodworker for over thirty years and has worked in small cabinet shops making everything from kitchen cabinets to hand-made furniture. Now working from a home woodworking shop Eric is sharing his passion for woodworking, tool advice and how-to knowledge from his Minnesota-based woodshop.
