Beginning the design for my garage workbench. This is meant to be a 'medium-duty' workbench. Size is moderate because I don't have a lot of space in my 2-car garage.

http://lapsww.blu.livefilestore.com/y1piYMfnEc9qxS1plu7tCTZy6y9N5qOuZEc-JfiJ0yrNGPteROQWqse8Jt0UAX-ez2DsbG01w4OBU5WNN58cWY4a6kRmhicfbBA/bench1.jpg

http://lapsww.blu.livefilestore.com/y1pn2GmYMpJK7eGU76PWsRcZTgn1w50MhfzSzG98YfxB3BDrK1 oVilO5WGEb8I5Fwm8YmbDquJIWA9fQELmIByXCgRaJl70zUbX/bench2.jpg

One question I have is this: I want to add a piece for a splash board but want it adjustable so it can be lowered to allow for a completely flat top. What would be the best way to cut ovals for adjusting slots like this?

http://lapsww.blu.livefilestore.com/y1pp5qhDudquSoeXNZdwIXHW-xUpcJSmgvSUbNzs2IuApgJgJa1wZP2fBujNHmyAgqYDGzeeDd2 nsyERxt7wYhlMh4NupFpBiok/bench3.jpg

My guess would be to use a router if you have bit that will work. Setup a guide on one side, and stops at either end. You could drill a hole in the center to use as a starting point.

Or, you could drill a hold on either side, and then use a skill saw to cut out in between. A guide wouldn't be a bad idea there too.

Nice design for a bench. Wood or metal?

It looks like metal to me? :confused:

If it is metal, and especially if the backsplash is metal, you could use a drillbit for each end to start the cut, and use an angle grinder to make the straight cuts.
If it is wood, using a drillbit at each end, then a Skilsaw would be fine, or even a compound sliding mitre saw if you have one.
It that backsplash is indeed wood, you're probably going to want to add some sort of bracing around that knob that gets tightened. Without a big washer or something, you're going to wear away the wood in the most used areas.

One other suggestion - make the top surface extend out a few inches. I always seem to hit my shins/knees against the shelves if they are flush with the front of the bench.

The bench will be built from metal. I have used the drill and angle grinder method before but haven't been pleased with how the grinder cuts past the drilled holes...

I have a jigsaw that I could get a metal blade for - that might work.

The backsplash will be steel as well. Thanks for the tip on the shelves. I'll see what I can do. I already have a precut top so I can't make the top stick out any further and I don't want to make the shelves too small. Perhaps just a few inches will make a difference?

but haven't been pleased with how the grinder cuts past the drilled holes...


Cut from both sides then finish it off with a sawzall

Perhaps just a few inches will make a difference?

It will.
Go stand against a table, any table that you have in your house.
If you look down and see where your shins are when standing in front of the table, you'll see why your shins will get sore quickly. :laughing:

I think when I built my previous bench, 3-4 inches was plenty of difference between the top surface and the lower shelf to avoid bruising. ;)

You should be able to move the long cross brace back a few inches on that lower shelf while still maintaining a good amount of useable space under there.

make the backsplash out of aluminum. then you could easily use a regular wood router to cut the slot. or, if you're set on steel, just drill a few holes and abandon the slot. it will still be adjustable, just not as quickly.

cool looking workbench. have you thought about adding a 2" receiver mount. i plan to on mine so i can quickly change out tools like bench vice, disc sander, belt sander, notcher, bench grinder, etc. i simply don't have the floor space for all those tools to be out at once when im working in there. storing them under the bench and being able to whip them out and stick them in the receiver mount when needed is my saving grace.

Drilling 2 holes on each side of the plate would definitely be easier and faster...
And it seems like the backsplash would only need to be 2 position anyway right?

make the table top bigger, just the top. its going to suck trying to clamp things to the edge if the front is the square tube. you could make the top swivel out a bit if you need to clamp somthing to weld or the such, then swing it back. i like the back spalsh idea.
also with that much leg under the shelf you could add another shelf. your never going to sit at this with a chair or stool? if you are get the stool/chair, sit on it with a tape measure.

X2 on leaving some overhang on the top out front for clamping room.

How tall are you? I'm 6'5" and I have a bench that measures 42" to the top. Its great for working on small things like a carburetor but it is almost too tall when working on larger items like a transfer case. I also have a Wilton C2 vise mounted to the top and it is way up there.

My other bench is 36" to the top and is much easier to work from on most things. In hindsight, I wish the other bench was no taller than 40".

Yeah I was concerned about the surface area to clamp to as well. Maybe a piece 4" wide would work better on the front?

http://lapsww.blu.livefilestore.com/y1pNVunGedl8xh4L94aO3vxpERSNhmt_5a6A8S0t5qPMn-EfBcKrm83znTbxjV7z9zPR9nRMlpx1-oPwcQlJQFxLIrbZOL-ShVx/bench4.jpg

I will have to look at the height again - I would like to be able to sit on a stool to work on occasion. I don't want it too short so I'm bending over all the time, but I don't want it too tall so its hard to work on large objects...

Nice looking table. I like the adjustable back stop. Let me know if you want us to cut one of these to fit your table then you will not have to worry about clamping so much.

http://www.jmrmfg.com/featured-tools/fabrication-tables/

Why aren't you putting a bottom shelf on it... seems like a lot of wasted space. If it was a fixed bench I could understand, but not a roller.... If you don't put a bottom shelf on it, make sure you put some cross bracing on the legs to support the casters.

Fix the supports for the casters... offset (as drawn) will collapse as soon as you load it. Make sure they can support 4x the weight of the empty bench. As soon as you build it you will find out how easy it is to overload it.

As mentioned, toe kick/counter overhang (both sides since it will be a roller).

Good luck.

I think I will put a bottom shelf on it after all. My new question is this: Would it be strong enough to replace the square tubing braces on each level with angle iron pieces? The outside frames and legs will stay square tubing, but I'm trying to think of ways to cut down on cost/weight...

I was planning on using 1.5" square tubing with a .125" wall. Thoughts on my choice of materials?

I think I will put a bottom shelf on it after all. My new question is this: Would it be strong enough to replace the square tubing braces on each level with angle iron pieces? The outside frames and legs will stay square tubing, but I'm trying to think of ways to cut down on cost/weight...

I was planning on using 1.5" square tubing with a .125" wall. Thoughts on my choice of materials?I would put a middle leg with a caster in the center of your table. I made my 3x5 table with 1.5 x .125 square tubing, and the middle of it sags. My top isn't super thick, and I used 4 inch slats with 1.5 inch slots in the middle of it. Your one piece top may combat sagging more than mine.

As far as the angle iron, you should be fine for the middle shelf, but on the lower shelf/bottom, I would use the square.

Crappy cell phone picture:

I picked up my square tubing for the workbench today. This is the first time I loaded my metal storage racks up with stock. Works pretty well, but they are a bit high - I need a ladder to stack the top stuff...

Anyways, I'm almost ready to start building this sucker. Space is definitely limited in a 2-car garage!

http://ufwuow.blu.livefilestore.com/y1pqkZrG-lSn8EQEhqMvhilxWPTs-QfqnHIq6PXuouO94FkJXmPqOMSGvH3XGKUETio8rurGUr9WPKa fvYUq5gl93MMIaKqORXB/metal%20rack1.jpg

Ok, so the bench is going to be 8' long. With the braces spaced like this for the bottom and middle shelf, what gauge sheet metal do you all think would be good for the shelves? I was thinking 16 gauge..

http://lapsww.blu.livefilestore.com/y1pmUU2pnn_qZdzNVAdrhoyYPtQ17LMzEhyayJNjdigcqOLr0G c9YxajGOJkvWUEz2xzf6ihkllo9LMfcHgDD_IfLcJ2P5IIG1L/bench-parts.jpg

I would use 3/4 ply covered with 20ga.

If you are going to put anything heavy on it I woudl also think about a riser post in the middle of the front and another set of casters in the middle.

5/16" plate. I've built half a dozen tables with it and its perfect.

5/16" - do you realize how heavy that would be??

We are talking just storage shelves here...

I might do the ply covered with 20 gauge. That might work well.

I meant for the top surface.

I agree with making it higher than normal. I did that with mine and everyone likes them like that.

I made mine so that I could buy a tool box roller bottom and hang it underneath. Drawers are a good idea too, but if you get too much weight the table becomes useless. I had 6 golf cart batteries on mine (360 pounds+) the other day and it worked well.

Use softer casters with locks on them. The really hard ones just skid if there is a rock on the floor. I used 3".

I started chopping and tac-welding today. Made some good progress in the 2 hours I worked on it:

http://lapsww.blu.livefilestore.com/y1pIEtrp-BZdpl7eqTTSRQqQljggz6VSUDgosnzV12cszW0j3uzpk-j6zXbNDjyqussnMuElSdxjAcTa8lQ866FSdJO11bZo8yC/bench1.jpg

Looks good. Don't forget the triangulation.

Keep posting pics.

Consider using expanded steel for the shelves as it doesn't hold grinding dust. Just a thought.

Looks good otherwise.

what program did you draw all your stuff up in? is it something that can be founf for free online?

.

what program did you draw all your stuff up in? is it something that can be founf for free online?

Yep - Google Sketchup - Free
http://sketchup.google.com/

Bolted on my casters today. It was about time, this bench was getting heavy!

http://lapsww.blu.livefilestore.com/y1po8-LhnX0th6PglJKrBxxreGSuE0_DGZhicIL_FDX1_rkLzzt1n0Mq 1I7PqLSQ_yKdzKUYcdQSo8UbraxASkClBNhxktMNOKx/DSC05313.JPG?psid=1

http://lapsww.blu.livefilestore.com/y1p6rJK2zBdKXYXfBWDZ1UMHYa1WlF2PsEyCbdR9878B5ozCit WzCF18wiZGjAy0jkhA2k4VzHVmlkVqFo0jSYXEo0LpT37vnbJ/DSC05315.JPG?psid=1

http://lapsww.blu.livefilestore.com/y1pqQh8e2omdI9XacUkY13fc7zmekthjMfoShboDBOEssBOujz wqa_jqWkOqZGWqCwzQtKRePbSUj5470exxX0AciFVEYpsaa2g/DSC05317.JPG?psid=1

http://lapsww.blu.livefilestore.com/y1p83Z8fBZPHuktIWxVp6o8ZSnegNLBxU67izbEF2a2Ar2rhxs TKgKV9fxY6Z-1WIyxg2wN2iC6wYYrFlo5KfHvMsJx12uk_jTV/DSC05318.JPG?psid=1

I think for right now I am going to get some OSB to use for my shelves because it's cheap. I may decide to get some plate later - we'll see.

Needs more triangulation. :D

Looks good so far!

Subscribed

Ok so I have few questions. I thought about painting the frame of the bench and creating an unpainted welding clamp point so the top could be used for welding. My question is this: Will welding on this bench with other equipment on it such as grinders, chop saw, drills, etc cause problems? Will it damage motors and such?

The second question is, if OSB is used, how much does that reduce/eliminate the risk of electricity to those objects?
Obviously the effects of welding near spray paint cans/ other aerosols would be a bad thing, so I'd have to be cautious about what I stored on the shelves...

You won't harm the tools, electricity takes the path of least resistance, so if your ground spot is near the top, the tools stored on the bottom won't even know the welding is happening. I have my chop-saw on a shelf next to my table and always have angle grinders and drills on it while welding, never a problem.

I would leave a few spots to clamp the ground, lets you keep your ground closer.

You won't harm the tools, electricity takes the path of least resistance, so if your ground spot is near the top, the tools stored on the bottom won't even know the welding is happening. I have my chop-saw on a shelf next to my table and always have angle grinders and drills on it while welding, never a problem.

I would leave a few spots to clamp the ground, lets you keep your ground closer.

awesome

Well I cut some OSB to size and used it for the lower two shelves. I needed something quick to store my crap on because I was running out of room.
I don't like the OSB for multiple reasons - cheap, chipping, rough, ugly, etc. I will be replacing this with plate at some point in the future but right now there are too many other pressing things on my plate.

http://lapsww.blu.livefilestore.com/y1pLGelex65lIc82_YqJqDrHhi7_FaiyOffvPOf_eSMBjl4Ejn FAztAAyDUOguCLEfPQPG8IINg_K9dGHItjS_YJS4yaKrZeKWf/osb-shelves.jpg?psid=1

I need some shelves on the walls to get most of the "odds and ends" stuff off the workbench.

I used an old counter top from a nice corner kitchen set. :smokin:

Mounted a 2" receiver hitch for accessories:

http://lapsww.blu.livefilestore.com/y1pU0JVZ2wwRBAROF8hhjzcJMMv_YkmhYsqdM5O7bg5bGdj49P BIR6wtuA2c8iM3Iaf3fjf3gNjqzlGhXYdJp6A71JuP9iyPBjF/IMG_0999.JPG?psid=1

Bench Grinder mounted up - works good:

http://lapsww.blu.livefilestore.com/y1p1UHj26geE6Gk5LYyJQZgk-RYxWx0UgcMtVMB6YWAa3Iuw9g6cVh-j5kc3oUpdoCWhLO8Xq0inbxckM9LzGhQLm1taeKy5PeJ/IMG_1001.JPG?psid=1

I'm working on a setup for my tube notcher right now. I will post up pics when finished. Obviously the mounts could stand a few gussets.

Now the hitch thing is a sweet ass idea, never thought about that.. I am gonna copy that for sure :smokin::smokin:

http://lapsww.blu.livefilestore.com/y1pT7m1zIUrL0HCy3TdEIQjxerMW5sYxrEOn-lS0rx3ekYLsUVX5-zo7YBAud5UEO_Er9UrJfL5vAGek6Uq6avjGa2X1Q4xrcS2/DSC05442.JPG?psid=1

http://lapsww.blu.livefilestore.com/y1p8uKOxH4YfGoHPMzng8_eaRGiCeRHtQHHWyGfzivjVJqgSz6 OZaMg3bkk7sOxmDXzZJg-RUtZYr1zbW5GkoHCfbGXO_zpGwXx/DSC05444.JPG?psid=1

http://lapsww.blu.livefilestore.com/y1pGp75awxd5TVd1awtEd7jCU2pShT24XOZ0aNn4uEXtZDE-ApvpsqbiHzQ_S3dSZP7GDSqaE_RiH25e_XWqHAFMbw1mlAlwat c/DSC05446.JPG?psid=1

Any kind of follow up about how this bench is working out for you? I am looking at borrowing your design and making one for myself but maybe a little deeper since I have more space. What size plate did you use for the top? Also, what is your overall height for the bench and how do you like that (personal height)? What would you go back and change? Thanks, it looks sweet!

So far everything is working really well. I can't think of anything that I would change per say - maybe add a few things.

Future plans may include adding a 'built-in' power strip.

Other than that, I wish I would have painted the entire frame before attaching the top. I'm starting to see some faint surface rust on the tube. Once the weather warms up, I'll probably strip it down and put a coat of paint on it.

I think the total height (without checking since I'm at work) was 40". I'm about 6' tall and it works out really well. It's been super nice to just throw some projects up there and weld standing up - saves the back BIG TIME. Once done, just hit the top with a wire wheel to cleanup.

I'm also VERY pleased with the caster size I chose. It rolls around the garage really well.

The top was like 1/8" plate - works well for what I'm doing. It is braced pretty well underneath and welded in quite a few spots to the frame.

If you build one yourself, post up some pictures, I'd love to see your progress!

What are the specs for the casters? Material, weight rating, size? Looks good. Hope to build something like this some day.

Caster | Brand : Titan Casters™ | Type : Polyurethane | Width : 6-1/2 in. | Length : 6 in. | Height : 6 in. | Wheel Size : 5 in. | Material : Steel and Plastic | Weight Capacity : 330 lb.

http://www.tractorsupply.com/tools/material-handling/casters/titan-casters-trade-5-in-polyurethane-caster-swivel-with-brake-1025590

Mounted a 2" receiver hitch for accessories:

http://lapsww.blu.livefilestore.com/y1pU0JVZ2wwRBAROF8hhjzcJMMv_YkmhYsqdM5O7bg5bGdj49P BIR6wtuA2c8iM3Iaf3fjf3gNjqzlGhXYdJp6A71JuP9iyPBjF/IMG_0999.JPG?psid=1

Bench Grinder mounted up - works good:

http://lapsww.blu.livefilestore.com/y1p1UHj26geE6Gk5LYyJQZgk-RYxWx0UgcMtVMB6YWAa3Iuw9g6cVh-j5kc3oUpdoCWhLO8Xq0inbxckM9LzGhQLm1taeKy5PeJ/IMG_1001.JPG?psid=1

I'm working on a setup for my tube notcher right now. I will post up pics when finished. Obviously the mounts could stand a few gussets.


I never would of thought to use a receiver, Great idea, i might have to make me one of them

I wish I were allowed to post pics of my new bench/welding table at work. 2" plate top, waterjetted for fixtures to be bolted down to, weighs a whole he'll of a lot. Stupid DOD and their silly rules.