Hi! I am Mark Donovan from homeadditionplus.com. Today, I am going to show how to make a simple garage workbench.
The first thing I want to do is cut two four-foot lengths at 2 x 4. Next, I am going to cut two lengths of 21” 2 x 4. I matched the edge with two 21” 2 x 4 lengths in between of four-foot lengths of 2 x 4 and what I am doing is I am marking a line for the width of this 2 X 4. And what we are going to do is make another mark 3 ½ inches over on each of the four foot long rails so that we can take a chunk out of each rail to create attachment.
Now what I have done on the four-foot rails is create another line such that we have a 3 ½ inch mark and put an X over. I am going to use my circular saw and cut a 3 ¼ inch depth notch out of this length of 2 X 4 here and on the far side. I will make many notches with the circular saw and then knock it out with a hammer and clean it up with a chisel. So now with our saw placed at 3 ¼ deep, we are going to cut groove in between these lines. Many of them then knock them out with a hammer. We are using a hammer to just knock it out. With the bulk of the material removed, we can just take a chisel and just clean up the notches. Make them clean and we repeat this process for all four sections of the mark with the two four foot rails. Now that we have notched out the four foot rails in either side for the legs. We are going to now cut four 36” long legs and again, we are going to notch out a 3 ¼ by 3 1/2 inch wide section from the legs so that we create a nice latch right here and all four corners of the top of the bench.
So now we are going to cut the legs to length. Again, the legs are 36” in length. Line it with our saw then we have the four legs. So now, what we are doing is we are marking three and a half inches in from the end of the leg. Use our square rule straight line. Put the X there and again, we are going to take our circular saw and make many cuts along this length of the 2 X 4, three quarters inch deep. Then we will take our hammer and chisel to clean it out and now we have nice latch to go to into the four-foot long rails of the top portion of the bench. So now, what we are going to do is we are going to cut a bunch of grooves, three quarters inch deep at the end of the length of the workbench leg.
Use the hammer to chop it up. We will just clean up with the chisel, we will do this for all four legs, and then we will be ready to assemble the workbench.
So I am applying a little glue to my lap joints on both sides – a wood glue. Press it together. I am pre-drilling the holes for the screws to put these lap joints together. I want to pre-drill the holes so that I make sure I do not split the wood. Ones we have the frame all put together, I am going to then drill another hole and put a carriage bolt in to really make this a rugged frame. Now I have pre-drilled my holes for the screws and for the lap joint. I am putting in one and quarter inch exterior screws. I am making sure I do not over tighten. We repeat this process for the entire four legs and four rails or two rails and now we connect the sides together to begin to put the structure together.
So now, I am going to attach the center rails to the end rails or the four-foot long rails. And then I am going to first again pre-drill holes and then using glue and two and a half inch screws, attach the four foot rail to the 21 inch section. Now, what we are doing is just pre-drilling the holes for the screws to attach the end rails to the four foot long rails. Apply a little glue. Put on a drill bit and then attach our screw. And we have nice tight fit without splitting the ends. That is the goal here.
So now that we complete the basic rail system and legs, we are going to put a center section of rails so we can have both the top surface and the center surface for storing materials. So now I built an inside frame that is cut two 45 inch long lengths and two 18 inch lengths. I am going to glue and screw these together and then this will sit inside the legs of the workbench. I have taken my mid frame, inserted it between th
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