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Ultimate 2-car Garage Workbench Build

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70K views 57 replies 39 participants last post by  TheTurtleLab  
#1 ·
A while back I decided it was time to build a new workbench, since my old made-of-2x4 bench was just not adequate. It started when I saw a build over at garage journal by a guy under the username "Steevo". I am sure many of you have probably come across the bench.

I was also in need of some more tool storage. At the time I had a 26" wide snap on lower, and a craftsman upper. I had done research on what box to get, and the diamond in the rough HF 13 drawer cabinet struck my attention. So, the next day I went and put my hands on it, and boy was I impressed. So much so, I ditched the snap on and craftsman for the superior HF box... two of them actually.

I decided to spin off Steevo's design and add hitch receivers as well as a few ac receptacles as well. Check it out:

Like any project, it started as a pile of metal square tube, 2.5" square tube, so that it would match the hitch receivers. I decided to splice a hitch receiver vs use 2.5" - 1/4" wall square tube, because the hitch receivers are just slightly larger, and 2" square tube slides in much easier. It's actually such a tight fit, that the weld bead would have to be completely removed before a hitch could even slide in.
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I jigged up the three legs on my old welding table. Boy do I not miss that table.
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Tacked up. This is when the size of this thing really struck me. 92" long, 24" deep. Awesome. Also the two boxes in the background.
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I dropped the boxes in from the top, using my engine lift. They fit perfect!
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A little paint... One of my favorite colors: battleship grey.
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#2 ·
This is when it got a little interesting... I work at a power plant in the engineering department, my boss being the manager of engineering. Well, I was sharing my build with him, and he looked at the steel angle along the front of the bench, and told me that he didn't believe it would hold the weight of a small block Chevy. Well, I am stubborn, so I decided to prove him wrong. I tossed an old workbench top on the frame (which is shorter than the bench), and supported the bench by only the outer legs, leaving the middle leg unsupported just to further prove my point. Look at the pictures, you get the idea.
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Zero deflection:
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Luckily, he got off my case about it after seeing the proof. Next step was to add the ac receptacles. In hindsight, I wish I had routed these within the frame, rather than in conduit. Oh well. You'll never see it anyway, and even if you do, it didn't turn out all that bad.
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In place. Yes, I know I need to put a cover on the junction box.
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Here it is with a top, and after being used for quite some time. I added some peg board, scored some pretty sweet cabinets to mount above, and added the top. The top is a 4x8" 3/4" sheet of ply ripped down the middle. I skinned it with 16ga sheet steel, and added a lip around it using 1.5" angle, 1/8" wall, and inverted the back piece to add somewhat of a "backsplash", if you will.
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Thanks for looking!
 
#7 ·
Do we even want to know how you got your Jeep up like that? :laughing:

Not to bust on you, but between the angle of the Jeep, that the tires place the load at the outer ends, and the workbench top, I'm not sure that is as impressive a test as you think it is.
 
#8 ·
I know, but it is still shocking image. I can do a statics problem and determine exactly how much force is being applied to each member, but either way, it will hold a small block chevy. Haha. Even at the angle the Jeep is, though, there is a substantial amount of weight at the front wheels.
 
#10 ·
Yeah, I am not really sure what's wrong here. Some people can see the images, some cannot. I am using the pirate 4x4 album to host them, and inserting them with the
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#12 ·
Yes it does make a lip, however I was just going for a more finished look, and don't have a sheet brake this wide. It does work well for keeping round object on the table, but also does the same for dust, if you care about that. I just have to sweep it up with a dust pan on the bench vs sweeping it onto the floor.
It will hold liquid between the angle and sheet. However, I have not fastened it yet, and it is only resting on it. When time comes to fasten all the the layers together, I will most likely toss a bead of urethane caulk in the gap to seal it up before I squeeze the layers together with some through bolts.

Good catch! It is a mace, actually. I dressed up as "The Fabricator" for halloween one year, where I wore a welding mask with the lens removed, with blood and cracks that were stitched up with artificial leather seine. Of course, boots, jeans, plad shirt and a leather upper-half jacket as well. I made the mace and MIG-welded it together, then press fit a handle I turned down on a wood lathe. It also opens up bottles! I actually just finished a CNC plasma table, and have a TIG now. I plan to make a better looking one with a more elaborate design and TIG the pieces on for a more refined look, just because.
 
#17 ·
#16 ·
My top is actually floating right now. I'll be attaching it sometime in the near future. I'll be bolting it down to the frame.
 
#18 ·
So are the boxes bolted in there or are they just sitting inside the frame?

I'm quite interested in this design, any chance you could post some dimensions so people could start looking for steel? How thick is the 2.5" square material you used for the main frame, not the thicker receiver portions.
 
#22 ·
Thanks for all the kind words everyone! I never thought this thing would fetch this kind of response.



The boxes are just sitting in it. I created a kind of tray using angle, and they are very stable within. I didn't see a need to attach them.

I'll see what I can do as far as dimensions. I think I have the CAD file somewhere...
 
#21 ·
Awesome build. I really like your design. A lifetime bench!

I made a built in bench in the "clean room" (Ha, is that an oxymoron!) of my shop in the same vein. I used 4 ball bearing Crapsman boxes and used wood. Very similar to what you did, but you can't move it. I put a ledger board on the well 3/4" higher than the boxes then put a 3/4" board on top of each box. Laid a 20" x length of the room top on it and screwed it to the boxes and the ledger board. I bet it would hold up a jeep as well! So I managed to get a bench top that was actually wider than the boxes by spacing them about 6" off the wall.
 
#42 ·
I just plasma cut the receptacle holes in the front, drilled and tapped two holes to screw a typical 110 receptacle in place, and ran 12gauge romex through a hole behind it, through the conduit to a junction box in the back middle. Then I wire-nutted them all together, with a 10 gauge extension cord as a pig tail. From there, I just plugged it into a receptacle that is near the bench. It's really pretty simple, nothing fancy.