After recently upgrading her table saw, This Old House DIY expert and House One editor Jenn Largesse decided to build a new workbench to house it. In part one of this six-part series, she demonstrates how to create the foundation for the ultimate mobile workbench. In parts two through six, she walks through some of the great additions you can make to complement your workbench’s look and functionality.
At 4-by-8 feet, this large work surface makes a great outfeed table. Follow along with Largesse as she demonstrates the construction process, offering valuable insights and tips along the way.
Materials and Tools Needed
This project requires a significant amount of plywood and various hardware components. Here’s what you’ll need.
Materials
- 1 1/4-inch pocket-hole screws
- 12 European hinges
- 2-inch wood screws
- 32 1/4-inch carriage bolts (1 inch long)
- 32 1/4-inch nuts
- Eight heavy-duty swivel locking 3-inch caster wheels
- Five sheets of 3/4-inch 4-by-8-foot plywood
- Primer and paint
- Six door handles
- Wood glue
Tools
- 3-inch hole saw attachment for drill
- Circular saw
- Corner clamps
- Drill/driver
- Hand clamps
- Paintbrush
- Paint roller
- Pocket hole jig and bit
- Speed square
- Table saw (optional)
- Tape measure
Mobile Workbench Cut List
Before you can start building your workbench, you’ll need to cut your various plywood pieces to size per the following cut list:
- Four 3/4-inch plywood doors (B) at 13 1/2 inches wide by 31 inches high
- One 3/4-inch plywood base at 45 inches by 93 inches
- One 3/4-inch plywood divider (J) at 55 1/2 inches wide by 31 inches high
- One 3/4-inch plywood divider (L) at 14 inches wide by 31 inches high
- One 3/4-inch plywood shelf (E) at 30 inches wide by 31 inches high
- One 3/4-inch plywood top at 48 inches by 96 inches
- Two 3/4-inch plywood dividers (C) at 3 inches wide by 31 inches high
- Two 3/4-inch plywood dividers (G/I) at 43 1/2 inches by 31 inches
- Two 3/4-inch plywood dividers (H) at 3 inches wide by 27 1/4 inches high
- Two 3/4-inch plywood doors (M) at 14 3/8 inches wide by 31 inches high
- Two 3/4-inch plywood shelves (F) at 30 inches deep by 32 inches wide
- Two 3/4-inch plywood shelves (K) at 13 1/4 inches deep by 53 1/2 inches wide
- Two 3/4-inch plywood sides (A) at 30 3/4 inches wide by 31 inches high
- Two 3/4-inch plywood sides (D) at 6 3/4 inches wide by 31 inches high
Preparing the Plywood for Your Mobile Workbench
The first step in building your mobile workbench is preparing your plywood sheets. This involves both priming and cutting the plywood to the required dimensions as follows:
- Apply two coats of primer to all plywood sheets. This step helps protect the wood and provides a better surface for paint adhesion.
- Once the primer is dry, use a circular saw to cut the plywood sheets according to the above cut list.
- Label each piece as you cut it to make assembly easier later on.
Assembling the Workbench Base and Frame
Once you’ve cut and prepared all your plywood pieces, you can assemble your mobile workbench’s base and frame. Establishing a solid and level base ensures your workbench’s stability, as Largesse demonstrates in the video above. You can do this as follows:
- Begin by positioning the base piece (45 inches by 93 inches) on a flat surface.
- Apply wood glue to the bottom edges of the wall pieces and use corner clamps to hold them in place on the base.
- Secure the walls to the base by driving screws through the base and into the bottom edge of each wall piece.
- Install the center divider and the sides of the opening that will house the table saw.
- Attach the shallow walls at the opposite end to create a recess for the future clamp rack.
Adding Internal Workbench Components
Once the basic frame is in place, it’s time to add the internal components that will provide storage and support for your workbench. These components will help organize your tools and ensure that the workbench meets your functional needs. Follow these steps to add your internal components:
- Install additional dividers and a shelf inside one of the cabinet openings.
- Add temporary blocks to hold the shelf for the table saw. You’ll fine-tune the height of this shelf after installing the top.
- Use a hole saw to create an opening in the wall behind the table saw. This will allow you to connect a vacuum for dust collection.
- Install doubled-up plywood pieces as supports on the open side of the assembly.
- Place 1-by-2 strips (or plywood strips) across each cabinet opening to strengthen the plywood top and create a stop for the inset doors.
Installing the Workbench Top and Casters
The top and casters are key components that transform this structure into a functional mobile workbench. The top provides a broad, stable surface for various tasks, while the casters facilitate easy mobility around your workshop. Follow the steps below to install these components:
- Drill pocket holes along the top edges of the walls and supports.
- Position the worktop (48 inches by 96 inches) and secure it in place with pocket-hole screws.
- Use a circular saw to cut an opening in the top for the table saw. Trim the corners with a hand saw for a precise fit.
- Trim the wall of the frame to allow the table saw’s extension to fully open.
- Attach the eight heavy-duty swivel locking casters to the bottom of the workbench using the carriage bolts and nuts.
Adding Doors and Hardware to the Mobile Workbench
Well-fitted doors will enhance your workbench’s functionality and appearance. Complete your workbench by installing the doors and adding the necessary hardware as follows:
- Use a jig to drill holes for the European hinges on the doors.
- Attach the hinges to the doors, then position and secure the doors to the inside of the frame.
- Use a hardware jig to drill evenly spaced holes for the door handles.
- Install the door handles on each door.
Workbench Customization Options
While this guide covers the basic construction of a mobile workbench, you can consider the following customization options to enhance its functionality:
- Clamp rack: Add a convenient storage solution for your clamps, keeping them within easy reach.
- DIY drawers for small tool storage: Create and install drawers to organize smaller tools and supplies.
- Downdraft sanding station: Integrate a sanding station that includes dust collection features.
- Dust collection system: Set up an efficient dust collection system to keep your work area clean.
- Tool organization systems: Incorporate systems to organize and store your various tools and accessories.
Next up, see how Largesse added tool organization, easy DIY drawers, dust collection, a downdraft sanding station, and a clamp rack in the guides below: