garage workbench plans - bob's woodworking · pdf filetable of contents – 2...

www.BobsPlans.com

Garage Workbench Plans

Every home woodworker knows the importance of making efficient use of the available space in his or her shop. This workbench is designed to provide the maximum functionality using the minimum amount of space possible. It provides a work surface of about six feet by two feet and is about 35” in height. It’s just the right size to provide ample work space for most projects.

The features that make this workbench ideal for the home shop are the built in clamping system, the nine drawers, the center cabinet space, and the mobility. The four inch casters enable you to easily roll it into position when needed and roll it aside when it is not in use.

The top surface is made of two layers of 3/4” MDF. This provides an extremely flat and solid work surface. The T-track inlaid in the top and around the edges provides a versatile clamping system that easily clamps very small or very large work pieces.

Copyright © 2006 by Robert E. Reedy All Rights Reserved This document may not be reproduced in whole or in part without the express written consent of the author.

http://www.bobsplans.com

Table of Contents – 1

Dimensions Drawings

Materials List – 1 ..................................................................................................... x Materials List – 2 .................................................................................................... xi Cutout Drawings Base/Back ................................................................................. xii Cutout Drawings – Top ........................................................................................ xiii Cutout Drawings – Panels ..................................................................................... xiv Cutout Drawings – Misc ........................................................................................ xv End and Center Panels .............................................................................................. 1 Base Dimensions & Layout ..................................................................................... 2 Back Dimensions & Layout ..................................................................................... 3 Top Dimensions & Layout ....................................................................................... 4 Sub Top Dimensions & Layout ............................................................................... 5 Top Trim and T-Track ............................................................................................. 6 Drawer Slides, Stiffener, Misc. Small Parts ............................................................ 7 Drawer Fronts, Front Trim, and Doors . ................................................................... 8 Drawer Boxes Dimensions . ..................................................................................... 9 Middle Shelf .......................................................................................................... 10

Table of Contents – 2

Assembly Instructions

Drawer Slides - Left Section - Left Panel .............................................................. 11 Drawer Slides - Left Section - Right Panel ............................................................ 12 Drawer Slides - Center Section - Left Panel... ....................................................... 13 Drawer Slides - Center Section -Right Panel ......................................................... 14 Drawer Slides - Right Section - Left Panel ........................................................... 15 Drawer Slides - Right Section - Right Panel .......................................................... 16 Base to Panels ......................................................................................................... 17 Stiffener - Casters ................................................................................................... 18 Attach the Back ...................................................................................................... 19 Assemble the Face Frame ...................................................................................... 23 Attach the Middle Shelf ......................................................................................... 20 Assemble the Face Frame ...................................................................................... 21 Attach the Face Frame ........................................................................................... 22 Attach the Leveling Blocks to the Panels .............................................................. 23 Attach the Front & Rear Leveling Blocks ............................................................. 24 Attach the Sub Top ................................................................................................ 25 Attach the Inner Trim ............................................................................................. 26 Attach the Middle Trim ......................................................................................... 27 Attach the Top ........................................................................................................ 28 Attach the Track to the Top ................................................................................... 29 Attach the Track to the Front & Ends .................................................................... 30 Attach the Lower Trim ............................................................................................31 Assemble the Drawer Boxes & Fronts ................................................................... 32 Attach Cabinet Doors ............................................................................................. 33 Attach Middle Door trim ....................................................................................... 34 Clamping System Parts .......................................................................................... 35 Assemble the EZ Mount Stop ................................................................................ 36 Clamping System Usage Instructions .................................................................... 37 Clamping System Illustrations ............................................................................... 38 Clamping Long Work Pieces ................................................................................. 39 Snapshots................................................................................................................. 40

Materials List - 1

Qty Size Material Item name

2 29 1/4” by 19” 3/4” Oak Plywood End Panels

2 28 1/4” by 18 1/4” 3/4” Plywood Middle Panels

1 66 1/2” by 19” 3/4” Plywood Base

1 66 1/2” by 28 1/4” 3/4” Plywood Back

1 72” by 24” 3/4” MDF Board Top

1 68” by 19 3/4” 3/4” MDF Board Sub Top

2 69 1/2” by 1 1/2” 3/4” Wood or Plywood 1st Front & Back Sub Top Trim

2 21 1/4” ” by 1 1/2” 3/4” Wood or Plywood 1st End Sub Top Trim

2 71” by 1 1/2” 3/4” Wood or Plywood 2nd Front & Back Sub Top Trim

2 22 3/4” by 1 1/2” 3/4” Wood or Plywood 2nd End Sub Top Trim

2 36” 1/2” by 3/4” T-Track Front T-Track

5 24” 1/2” by 3/4” T-Track End & Top T-Track

1 72” by 3/4” by 1/2” 1/2” Thick MDF or Wood Front Lower T-Track Trim

2 24” by 3/4” by 1/2” 1/2” Thick MDF or Wood End Lower T-Track Trim

17 18 1/4” by 1 1/2” 3/4” Wood Drawer Supports

5 6” by 1 1/2” 3/4” Wood Small Drawer Supports

10 18 1/4” by 2 1/2” 3/4” Wood Drawer Side Guides

4 18 1/4” by 3” 3/4” Wood Lower Drawer Side Guides

6 18 1/4” by 2” 3/4” Wood Lower Drawer Supports

2 14 1/2” by 2” 3/4” Wood Lower Back Supports

1 27 1/2” by 2” 3/4” Wood Center Lower Back Support

4 17 1/2” by 1 1/2” 3/4” Wood 17 1/2” Leveling Block

4 16 3/4” by 1 1/2” 3/4” Wood 16 3/4” Leveling Block

2 30” by 1 1/2” 3/4” Wood 30” Leveling Block

1 66 1/2” 2 by 4 (3 1/2” by 1 1/2”) Stiffener

6 16” by 1 1/2” 3/4” thick wood or plywood Drawer Trim

2 29 1/4” by 1 1/2” 3/4” thick wood or plywood Vertical End Trim

x

Materials List - 2

Qty Size Material Item name

2 30” by 1 1/2” 3/4” thick wood or plywood End Trim

2 23 1/4” by 1 1/2” 3/4” thick wood or plywood Vertical Divider Trim

2 65” by 3” 3/4” thick wood or plywood Upper & Lower Trim

1 3 1/2” by 30 1/2” 3/4” thick wood or plywood Center Drawer Front

2 3 1/2” by 16 1/2” 3/4” thick wood or plywood Top Drawer Front

2 4 1/2” by 16 1/2” 3/4” thick wood or plywood 4 1/2” Drawer Front

2 5 1/4” by 16 1/2” 3/4” thick wood or plywood 5 1/4” Drawer Front

2 7” by 16 1/2” 3/4” thick wood or plywood 7” Drawer Front

2 19” by 14 3/4” 3/4” thick wood or plywood Cabinet Doors

1 3/4” thick wood or plywood Door Lip

6 19” by 2 7/8” 3/4” thick wood or plywood Top Drawer Sides

4 19” by 3 7/8” 3/4” thick wood or plywood 3 7/8” Drawer Sides



2 28 3/8” by 2 7/8” 3/4” thick wood or plywood Center Drawer Ends

4 14 3/8” by 2 7/8” 3/4” thick wood or plywood Top Drawer Ends

4 14 3/8” by 3 7/8” 3/4” thick wood or plywood 3 7/8” Drawer Ends



1 29 1/8” by 18 1/4” 1/4” Hardboard Center Drawer Bottom

6 15 1/8”” by 18 1/4” 1/4” Hardboard Drawer Bottom

1 18 1/4” by 30” 3/4” plywood Middle Shelf

xi

Rev 9/14/2010

3/4 "

MD

F or

ply

woo

d

C i /

66 1

/ 2"

Bac k

66 1

/ 2"

/

i

1 2 /

utout Draw ngs - Base Back

Bas

e

66 1

2"

xi

48"

96"

9" 8 1 4"

Cutout Drawings - Top

1st F

ront

& B

ack

Sub

Top

Trim

3/"

72"

3/

48"

96"

19 4"

68"

Sub

Top

24

Top

4 " M

DF

xiii

Mi

lls

M

il

lsd d

e Pa

n ed d

e Pa

n e

Dra

wer

Trim

(6)

Dra

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Trim

(6)

Dra

wer

Trim

(6)

Dra

wer

Trim

(6)

Cab

inet

Doo

rs ( 2

) D

raw

er T

rim (6

) D

raw

er T

rim (6

)

xiv

End

Pan

el

1st E

nd S

ub T

o p T

rim

1st E

nd S

ub T

o p T

rim

Ver

tical

End

Trim

(2)

End

Pan

el

30" L

evel

ing

Blo c

ks (2

) 2n

d E

nd S

ub T

o p T

rim

2nd

End

Sub

To p

Trim

30

" Lev

elin

g Bl

o cks

(2)

Ver

tical

End

Trim

(2)

2nd

F ron

t & B

ack

Sub

Top

Trim

2n

d F r

ont &

Bac

k S

ub T

op T

rim

Cab

inet

Doo

rs ( 2

)

(1)

Cen

ter D

raw

er F

ront

Mid

dle

Trim

(1) V

ertic

al D

ivid

er T

rim (2

)

Ver

tical

Div

ider

Trim

(2)

(1)

3/ l

Cen

ter L

ower

Bac

k Su

ppo r

ts

4" by 4' by 8' p ywood

Cutout Drawings - Panels

i(

i/

iia

lill

w)

66 1

/ 2"

Stf

fene

r M

ake

the

stffe

ner f

rom

1 1

2" th

ck m

a ter

-A 2

BY

4 w

ork

3/4"

thic

k m

ate r

ial

96"

Dra

we r

Sid

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uid e

s (1

0)

Dra

we r

Sid

e G

uid e

s (1

0)

Dra

we r

Sid

e G

uid e

s (1

0)

Dra

we r

Sid

e G

uid e

s (1

0)

Dra

we r

Sid

e G

uid e

s (1

0)

Dra

we r

Sid

e G

uid e

s (1

0)

Dra

we r

Sid

e G

uid e

s (1

0)

Dra

we r

Sid

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uid e

s (1

0)

Dra

we r

Sid

e G

uid e

s (1

0)

Dra

we r

Sid

e G

uid e

s (1

0)

(6)

(6)

(6)

(6)

(6)

Low

e r D

raw

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Low

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er S

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rts

Low

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Low

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raw

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Low

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raw

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uppo

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3/4"

thic

k m

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67 1

/ 2"

Low

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er S

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) (6

)Lo

we r

Dra

wer

Sup

ports

Lo

we r

Bac

k S

uppo

rts (2

) Lo

we r

Bac

k S

uppo

rts (2

)

17 1

/ 2" L

evel

ing

Blo

cks

(4)

17 1

/ 2" L

evel

ing

Blo

cks

(4)

16 3

/ 4" L

evel

ing

Blo

cks

(3)

17 1

/ 2" L

evel

ing

Blo

cks

(4)

17 1

/ 2" L

evel

ing

Blo

cks

(4)

16 3

/ 4" L

evel

ing

Blo

cks

(3)

16 3

/ 4" L

evel

ing

Blo

cks

(3)

This

boa

rd s

houl

d pr

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ough

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ra w

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to m

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he c

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tem

.

Cutout Drawings - Misc

3 1/2" 7 1/2"7 1/2"

xv

End and Center Panels Page 1

2 /4"

/

Mi l ls

( i )

/

el

( i )

8 1

18 1 4"

dd e Pane

2 Requ red

29 1 4"

19"

End Pan

2 Requ red

The two end panels are 1" taller than the center panels. This is because the center panels sit on the top surface of the base and the end panels extend 1/4" below the bottom surface of the base..

The end panels are also 3/4" wider than the center panels. This is so they will be flush with the ends of the back section.

C 2006 by Robert E. Reedy, Vandalia, OhioCopyright

Base

Dim

ensi

o ns

& L

ayou

t

Pag

e 2

/

/

/

3/

2"3/

10"

9 1 /

4"

10"

9 1 /

4"9

1/4"

3/8"

18

" 2"

66 1

/2"

9 1 2"

9 1 2"

18 5

8"

19"

2" 2"

8"

8 "

9 1/

4"

5/8

Ba s

e

Cu t

the

bas e

fro m

3/4

" m

a ter

ial,

the n

dril

l and

cou

nter

sink

hol

es fo

r #8

scr e

ws

as sh

o wn

in

the

dra w

ing

abo v

e. A

ll th

e sc

r ew

s ar

o und

the

edg e

are

3/8

" fr

o m th

e ed

g e.

Cop

yrig

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C20

0 6 b

y R

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t E. R

eedy

, Van

dalia

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o

Back

Dim

ensi

o ns

& L

ayou

t

Pag

e 3

1/2"

3/4"

1/2"

/

3/

/

/4"

/

Bac

k

17

30

17

1 1 4" 4"

10"

17 1 8"

22"

28 1

66 1

2"

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the

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C20

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Top Dimensions and Layout Page 4

2

7

F e 3/ n

2

T-Tr

ack

& M

iter S

lot C

utou

t Dim

ensi

ons

T- T

rack

Slo

t

Td

. t e s

s d t s

3/ // /

g

4"

2"

irst, cut the top from a piec of 4" MDF. The cut the

T-Track slots according to the drawing to the right.

4"

he T-Track slot dimensions are base on the center of the slots However, the exaclocation of thes item is strictly a matter of personal choice.

T-Track size vary from bran to brand. The mos common size are

4" wide by 1 2" deep or 3 4" wide by 3 8" deep. Cut the slots so the track you're usin is flush with the top surface.

24"

6"

Copyri Cght 2006 by Robert E. Reedy, Vandalia, Ohio

Sub Top Dimensions and Layout Page 5

Sub Top

68"

Dril

l and

cou

nter

scr

ewho

les

for #

8 fla

thea

d sc

rew

s in

the

loca

tions

sho

wn

belo

w.

1

/

/8"

/ 8"

/8"

l

le

/

/

1 /8"

1 /8"

10"

3"

3"

0"

3"

3"

3"

3"

1 1

8"

1 1

1 1

1 1

Sub

Top

Scr

ew H

oe

Layo

ut

Scre

w H

oLa

yout

19 3 8"

19 3 8"

4 5

4 5

/

1

9 1 2"

6"

26"

1

/

26"

6"

9 1 2"

19 3/4"


Top

Trim

&T-

Tra c

k P

age

6

The

Sub

Top

tr im

is m

ade

o f 3

/4" t

hick

by

1 1/

2" h

igh

mat

e ria

l. T h

is b

e cau

se th

e T -

Trac

k is

1/2

" by

3 /4"

.

/rim

(i

)

1 1/

45°

69 1

2"

45°

1st F

ront

& B

ack

Su b

Top

T2

Req

ure

d

2"

45°

45°

im

ired

/im (

i)

1 1/ 1 1/

im (

id)

/

1 1/

r(

) 45

°

21 1

4"

1st E

nd S

ub T

op T

r2

Req

ure

d

2"

45°

71"

2nd

Fron

t & B

ack

Sub

Top

Tr

2 R

equ

re

45°

22 3

4"

2"

2nd

End

Su b

Top

T2

Req

u

45°

2"

If y

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ave

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, I re

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the

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The

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ocke

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ill b

e us

ed to

secu

re th

e To

p to

the

Sub

Top .

The

exa

c t lo

catio

n of

the

poc k

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ole s

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riti c

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ing

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at th

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r T-T

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e se

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En

d T-

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k (2

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23 1

/4"

35 1

The

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ade

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ater

ial.

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bec

a use

the

T-Tr

ack

is 1

/2" b

y 3/

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3/

im (

i)

4"

45°

45°

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t T-T

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1 R

equ

red

72"

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"

im (

ir)

4"

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45°

23 3

End

T-Tr

ack

Tr2

Req

ued

Cop

yrig

ht

C20

06 b

y R

ober

t E. R

e edy

, Van

dalia

, Ohi

o

Stiff

ener

(Mak

e th

e st

iffen

e r fr

om 1

1/2

" thi

ck m

ate r

ial)

66 1/2"

3 1/2"

Copyright C 2006 by Robert E. Reedy, Vandalia, Ohio

Drawer Slides / Stiffener / Misc Small Parts

18 1/4"1 1/2" Drawer Supports (20)

30"1 1/2" 30" Leveling Blocks (2)

Page 7

2 1/2"

18 1/4"

Drawer Side Guides (12)

18 1/4"

3" Lower Drawer Side Guides (4)

2"

18 1/4"

Lower Drawer Supports (6)

Lower Back Supports (2)2"

14 1/2"

Center Lower Back Supports (1)2"

28 1/2"

1 1/2"17 1/2"

17 1/2" Leveling Blocks (4)16 3/4"

1 1/2" 16 3/4" Leveling Blocks (4)

Rev 9/14/2010

Drawer Fronts, Front Trim, and Doors

Page 8

1 1/

/ i l im (2)D im (6)/29 1 4"

1 1 2" Vert ca End Trrawer Tr2" 16"

Mi l im (1)//

1 1/ i l Divid im (2)dd e Tr1 1 2" 30" 23 1 4"

2" Vert ca er Tr

im (2)Upper & Lower Tr

65"

3"

2" Middle Door Trim (1)

18 1/2"

Drawer Fronts Dimensions

30 1/2"

/

(1)

3 1 2"

Center Drawer Front

4 1/2" 3 1/2"

4 1/2 (2)" Drawer Fronts Top Drawer Fronts (2)

16 1/2" 16 1/2"

/

/ /4 (2)

16 1 2"

5 1 4" 5 1 " Drawer Fronts

19" i s (2)Cab net Door

7"

16 1/2" 14 3/4"

aw (2)7" Dr er Fronts


Drawer Boxes Dimensions Page 9

Si (6)

2 7/

1

/ i (4)

1

/

Top Drawer des

8"

9"

3 7 8" Drawer S des

9"

3 7 8"

1/

3/

1/

il V

i

4"

8"

4"

Det

aew

-D

raw

er B

o tto

m C

utou

t

6 5/8" 4 7/8" / i (4)4 7 8" Drawer S des

6 5/8" Drawer Sides (4)

19" 19"

2 7/8" 2 7/8"

T (4)op Drawer Ends C (2)enter Drawer Ends

28 3/8" 14 3/8"

/ (4)6 5 8" Drawer Ends 3 7/8"

/ (4)4 7 8" Drawer Ends 3 7/8 (4)" Drawer Ends 6 5/8"

4 7/8"

14 3/8" 14 3/8" 14 3/8"

1/8"

(6) m (1)

/

1/8"

/

15

Drawer Bottoms Center Drawer Botto

18 1 4"

29

18 1 4"


Middle Shelf Dimensions Page 10

/Middle lf

3

18 1 4" She

0"

/ L (2)

( t i / i ial.) 18"

2 3 4" ower Track Support

Lower Track Suppor s made of 1 1 2" th ck mater

Lower Track Trim (21" )

18"

(Lower Track Trim is made of 1/2" thick material.)


Attach Drawer Slides Left Section - Left Panel Page 11

Copyright 2006 by Robert E. Reedy, Vandalia, Ohio

2 /4"

1

Left End Panel

4"

5"

6 3/4"

Drawer Support

Drawer Support

Lower Drawer Support

Drawer Support

Drawer Side Guide Drawer Support

Leveling Block

Lower Drawer Side Guide

Drawer Side Guide

Drawer Side Guide

1 /2"

5"

17"

5 1

9"

3"

1"

0 1

C

li i i el

/

/

3"

1 /4"

Drawer Support

Drawer Support

Drawer Support


Drawer Support


Drawer Side Guide

Drawer Side Guide

Drawer Side Guide

i li io

Page 12 Attach Drawer S des Left Sect on - R ght Pan

5"

10 1 2"

17"

25 1 4"

8 1

Copyr ght 2006 by Robert E. Reedy, Vanda a, OhC

Attach Drawer Slides Center Section - Left Panel Page 13

3"

Drawer Support

Drawer Support

Leveling Block


6 1/4"

11"

6"

13 3/4"

26 1/4"

Left Inside Panel


Attach Drawer Slides Center Section - Right Panel Page 14

Drawer Support

Drawer Support

Leveling Block

Lower Drawer Supportl

6"

13 3/4"

26 1/4"

Right Inside Pane


Attach Drawer Slides - Right Section - Left PanelPage 15

1 /2"

1

2 /4"

/

Drawer Support

Drawer Support

Drawer Support


Drawer Support


Drawer Side Guide

Drawer Side Guide

Drawer Side Guide

5"

0 1

7"

5 1

3"

18 1 4"


Attach Drawer Slides Right Section - Right Panel

Copyright 2006 by Robert E. Reedy, Vandalia, Ohio

5"

/

3"

/

Drawer Support

Drawer Support


Drawer Support

Drawer Side Guide

Drawer Support

Leveling Block


Drawer Side Guide

Drawer Side Guide /

Right Section - Right Panel

17"

25 1 4"

19"

4"

5"

6 3 4"

1"

10 1 2"

C

Attach the Panels to the Base Page 17

1 /4"

/

2 /4"

L

8 1

18 1 4"

9 1

ower Back Supports


Attach theStiffener & Casters to the BasePage 18

Attach the casters to the base as shown. Then position the stiffener as close to the front as possible while still allowing clearance for the swival casters to rotate. Mark the position of the stiffener, then drill about six holes for #8

Stiffener

wood screws through the base. Apply some glue and secure the stiffener to the base with 2" #8 screws.

The screw heads will be inside cabinet below the drawers so it doesn't matter if you use flathead or pan head screws..


Attach The Back Page 19

Attach the back to the vertical panels a

nd base with 1

1/2" #8 flathead screws as sh

own.


Attach the Middle Shelf Page 20

Middle Shelf

Attach the middle shelf to the supports.


Assemble the Face FramePage 21

Copyright 2006 by Robert E. Reedy, Vandalia, OhioC

Assemble the front trim pieces (face frame) as shown. The dimensions for the drawer trim spacing are shown in the drawing above. The important thing is that the drawer trim pieces line up with the drawer slides.

If the drawer slides are off a little, position the drawer trim pieces so they are flush with the top of the drawer slides.

Pocket holes are the easiest way to join trim or face frames as they are often called. if you don't have a pocket hole jig, you can use dowel joints.

Don't forget! The pocket holes go on the back side of the face frame.

Lower Trim

Upper Trim

6 3/4"

3"

4"

5"

6 3/4"

3"

4"

5"

3"

Rev 9-14-2010

Attach the FaceFrame to the Cabinet Page 22

k s d

Attach the assembled face frame to the cabinet with finishing nails. Then, countersin and fill the nail hole with woo putty.


Attach the Leveling Blocks to the End and Center Panels Page 23

Now, you are ready to attach the leveling blocks. This is the way you ensure that the top is perfectly flat when the workbench is completed. First, drill three 1/4" diameter holes completely through each leveling block, (the two shortest ones only need two holes). The exact location of the holes is not critical. Drill a hole about 2" from each end and one in the middle of each leveling block. To keep the glue from setting before you're finished, it's best to attach the end and center panel leveling blocks first and ensure they are level with each other before attaching the front and rear ones.

k

e s h l g /

t .

When all the blocks are level, tighten the screws and recheck that they did not move.

The important thing is that the top surfaces of the leveling blocks be level with each other. This will provide a flat surface to mount the sub top to.

After all the blocks are in place, use a straight edge to ensure the top surfaces of all the leveling bloc s are level with each other. If you have a four foot level, that would work great.

Apply som glue to the mating face and attac the end and center paneleveling blocks usin 1 1 2" #8 pan head screws with flat washers as shown. Do not tighten the screws yet as the blocks mus be leveled first


Attach the Front & Rear Leveling Blocks Page 24

Apply glue to the mating surfaces and attach the front and rear leveling blocks as shown in the diagram. Use your straight edge to ensure the tops are even with the tops of the end and center leveling blocks. Then tighten the screws.


Attach the Sub Top to the CabinetPage 25

A /

h

ttach the Sub Top with 1 1 2" #8 flathead screws. The Sub Top should be flus to the edges of the cabinet on all four sides.


Attach the Inner Sub Top TrimPage 26

/Attach the Inner Sub Top Trim to the Sub Top with 1 1 2" #8 flathead screws. Be sure the top of the trim is flush with the top surface of the Sub Top.


Attach the Middle Trim to the Inner Sub Top TrimPage 27

Attach the Middle Sub Top Trim to the Inner Sub Top Trim with 1 1/2" #8 flathead screws. Be sure to space

e r b

. s

thes screws so they don't interfere with the screws in the inne trim or the T-Track which will e attched to the Middle Sub Top trim The pocket hole will be used to attach the edges of the top to the trim.


Attach the Top to the Sub Top Page 28

Attach the Top to the Sub Top with 1" #8 flathead screws through the cutouts for the T-Track. Secure the edges of the top with pocket hole screws through the holes you drilled through the Inner Sub Top Trim. You can secure the right side with screws from the underside of the sub top. If you prefer, you can glue the Top to the Sub Top. However, gluing it will make it much more difficult to replace the top in the future if you need to.

P l

n e s d g a / e /

r , r

.

ocket Ho e Screws

Note: The dimensions give in thes plan are base usin T-Track th t is 3 4" wid and 1 2" thick. If you T-Track is a different size you will need to modify the thickness of the inne trim accordingly


Attach the T-Track & Miter track to the Top Page 29

Attach the T-Track to the top as shown with 1" #6 screws. Some manufacturers countersink the holes formounting the track and others do not. From my experience, I prefer flathead screws with countersunkholes. This keeps the screw heads from interfering with the bolts sliding through the track. The track Iused for the prototype was designed for pan head screws, so I countersunk them on my drill press.

T

e w t .

op T-Track

Attach the Lower Track Support to the left side of the cabinet with six 2" #8 flathead screws. Position this piec so it is 1" belo the Sub Top Trim and centered fron to back


Attach the T-Track to the Edges of the Front and Ends Page 30

Attach the edge T-Track on each end and along the front to the middle Sub Top Trim with 1" #6 screws. Position this T-Track under the bottom surface of the Top as shown in the detail drawing.

T-Track joins at the corners like

i li ioC

s

F

D ail

Copyr ght 2006 by Robert E. Reedy, Vanda a, Oh

this so you can slide the bolt in and out. End T-Track

ront T-Track

End T-Track

et

Attach the Lower T-Track to the Lower T-Track Support. The T-Track should be centered top to bottom.

Attach the Lower Front Trim to the Front and Ends Page 31

Attach the Lower Top Trim on each end and along the front to the middle Sub Top Trim with 1 1/2" finishing nails.

If you cut the top a little larger than the dimensions called for, you can trim it with your router and a flush trimming bit. Use the Lower Top Trim for the bit bearing to follow.

The Lower Top Trim joins at

i li ioC

il

im

L im

Copyr ght 2006 by Robert E. Reedy, Vanda a, Oh

Deta

the corners like this.

Lower Tr

Attach the Lower Track Trim with finishing nails.

ower Tr

Assemble the Drawers Page 32

Apply a little glue to the mating surfaces and assemble the drawer boxes.

Left Side

Ri i

t

k

ght S de

Fron

Bac

Step 1 Step 2 Step 3

Assemble the front, back, and right side with finishing nails as shown in Step 1. Insert the bottom as shown in Step 2. Attach the left side as shown in Step 3.

Step 4 Step 5

Support the drawer boxes with 1/4" thick strips of wood and attach the drawer fronts with 1 1/8" screws as shown. This is necessary because the bottom of the front must be 1/4" below the bottom of the box so it will overlap the rear cabinet trim when installed.


Attach the Cabinet Doors Page 33

n s n

n

Attach the cabinet doors so the tops alig with the tops of the drawers and the side alig with the ends of the middle drawer as show above.


Attach the Middle Door trim Page 34

nAttach the Middle Door Lip to the back of either of the cabinet doors so half of it is visible as show . Attach it to the back of the door with a couple of 1" wood screws. The left door is not pictured in the drawing for clarity.

This piece serves as a door lip so there is no visible gap between the doors.

Now, you're ready to attach the Drawer and Door handles and your work bench is finished.


Clamping System Parts Page 35

3/8" Button Hole

3/

"/4

5/ l le

"/2

2 3

16" Bo t Ho

3 1

"2

le8" Button Ho

/

Cl s (2)2"

4 1 2"

amp Jaw

Clamp Jaw Layout (Side 1) Clamp Jaw Layout (Side 2)

5/

/

/

/ i

3" 3"/R

Di 5/

2

8"

3 1 2"

1 1 2"

2 3 4"

End

Vew

1 1 2" ear Stop

a - 16"

4"

Di 5/

//

"

la - 16"

1 3 4" 1 3 4" 2"

28

EZ C amp Stop

P (2)ost (2)Jaws

Drill two pocket holes in each Post as shown below. Next, drill two 1/4" diameter holes in the end of each Post as shown. (The 1/4" holes

2" 2" should only be 12 1/2" 4"

/ )2" deep.

1/2"

Drill a 5/16" bolt through each jaw as

Di / 1/

ws

"/4

a - 5 16" 2"

Ja

2 13/8"

shown. Next, drill two 5/16" holes for the dowel pins in each Jaw as shown. (The dowel pin holes are 5/16" diameter so the

should be 1/2" deep.) Posts

sJaws can pivot over the pins. These hole


Assemble the EZ Mount StopPage 36

a s s n / /

/( /)

(

r ) /h s ( .

.

Att ch the Post to the ends of the Stop Bar with pocket hole screw as show below. Next, cut four 7 8" long dowel pins from 1 4" dowel rod. Apply some glue and insert a 1 4" dowel pin into each hole in the ends of the Posts. The dowel pins should protude about 3 8" from the ends of the Posts.

Place the Jaws over the protuding dowel pins as shown above. Do not glue the dowel pins to the Jaws as the Jaws must be allowed to pivot in orde to work as clamps. Insert a 5 16 carriage bolt through the

ole as shown. The carriage bolt should be 5" long Secure the pieces with a flat washer and knob


Clamping System Usage Page 37

The T-Track clamping system provides a flexible way of clamping both large and small work pieces. Most work pieces can be clamped using the two Clamp Jaws and the Rear Stop. The Clamp Jaws are used with the T-Track that runs along the front edge of the workbench. The Rear Stop is used with the T-Track that is embedded in the top surface of the workbench.

For longer workpieces, you can use the the Clamp Jaws with the T-Track on the ends of the workbench. The EZ Mount Stop may be secured anywhere along the workbench top. The simple clamps on each end of the EZ Mount Stop grip the edge of the workbench top as well as C-Clamps. This feature enables you to use the workbench as a large bar clamp for gluing up boards.

You can make the clamping system grip the work piece even tighter by gluing strips of 100 grit sandpaper along the edges that contact the workpiece. The sandpaper requires much less force than the surface of bare wood.

The button arrangement on the Clamp Jaws allows you to filp the Clamp Jaws over for thicker work pieces. The drawings on the next two pages illustrates how the clamps work.

To clamp a work piece, position the workpiece so the edge protudes slightly over the edge of the workbench top as shown. Then, position the Rear Stop against the workpiece and tighten it to T-Track using the knobs. Next, tighten the Clamp Jaws against the workpiece with the knobs and your work piece will be clamped just like with a vice.

For thinner workpieces, position the Clamp Jaws and Rear Stop as shown. If your workpiece is thinner than 3/4", you can place strips of wood under the work piece so it is slightly higher than the top edges of the Clamp Jaws.

For thicker workpieces, flip the Clamp Jaws so the second button is against the Lower T-Track Trim and reverse the Rear Stop so the thicker edge is against the workpiece.


Using the Clamps Page 38

For thinner workpieces, position the Clamp Jaws and Rear Stop as shown.

T

B n

Cli

-Track

utto

Second Button

amp Jaw Workp ece

Rear Stop

For thicker workpieces, flip the Clamp Jaw so the second button is against the Lower T-Track Trim and reverse the Rear Stop so the thicker edge is against the workpiece.

S

ClkpiRear Stop

T-Track

econd Button

Button

amp Jaw Wor ece


Clamping Long WorkpiecesPage 39

i c li hio

T p k

Copyr ght by Robert E. Reedy, Vanda a, O

o clam long wor pieces, use the Clamping Jaws and EZ Mount Stop as shown.

Snapshots Page 40

Clamping a Small Work Piece

Clamping a large Work Piece Vertically

Clamping a Large Work Piece

Clamping a Work Light Clamping a Thick Work Piece

c by Robert E. Reedy, Vandalia, OhioCopyright

Front ViewPage 1


Low

er T

rim

Upp

er T

rim

68"72"

End ViewPage 1


19"

End View

23 1/4"

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