Building A Low-Cost Sturdy Work Bench From 2x4's And OSB http://www.hammerzone.com/archives/workshop/bench/belo...

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In This Article: Related Articles: www.hoseclamp-manufactory.com
The Materials Index of Workshop Articles
Cutting The OSB Building A Shelf Unit
Cutting The Legs Installing Electrical Outlets on a Work Setting Benches
Online Metrology
Assembling The Side Frames Bench
Instruments Shop
Assembling The End Rails Building A 3' x 7' Outdoor Workbench
Tesa Setting Benches
Assembling The Top and Shelf www.europacprecision.com
Tools and Materials
Skill Level: 2 (Basic) Time Taken: About 2 Hours Composite/Sandwich
Panels
By Bruce W. Maki, Editor Metal Faced,
Lightweight, Plywood
The Materials: Architectural,
Acoustic, Foam, SIPS
www.normanton.co.uk
The materials used for this project:
New construction
Four 8' 2x4's tool
One partial 2x4, about 6' long. house framing tool
Two large pieces of OSB (Oriented Strand Board). I used V-Line clamp new
scraps recovered from job sites. One piece was 7/16" thick, construction tool
and one just happened to be 5/8" thick. under $10.00
vlineclamp.com/
3" Deck Screws
1-5/8" Deck Screws

Note on OSB Thickness: I have made several work benches like this one. Most have 129
used 7/16" thick OSB for the top and bottom shelves. Heavier OSB won't hurt, of course,
but just costs more with questionable benefit. J’aime

I would never use 1/4" OSB for a work bench. It just is not strong enough, and is not Visit HammerZone on
much cheaper than 7/16" OSB. Facebook

Cutting The OSB:

The first thing I did was to lay some 2x4's across two saw horses and
place the OSB on top.

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Building A Low-Cost Sturdy Work Bench From 2x4's And OSB http://www.hammerzone.com/archives/workshop/bench/belo...

I often use a 4' level for drawing lines. This method is easier and
more precise than using a chalk line.

The level used here is a product called a "Tri-Level" from Sears, which cost about $15.
One edge is triangular-shaped and has a ruler scale.

I cut the OSB to the desired width. In this case, the smallest of
the two scraps of OSB was about 26" x 48", so my goal was to
make two pieces the same size.

If I was using a new, full sheet of OSB, (that is, if I ran out of
plywood scraps), I would cut two 24" x 48" pieces from the 4'
x 8' panel, leaving enough for another work bench. Many
stores sell 4' x 4' panels and 2' x 4' panels.

Cutting The 2x4's:

I used a power miter saw to cut the 2x4's, because it is faster,

easier, and safer than using a circular saw. This tool is the best
$150 I have ever spent.

For laying out the cuts I used a tape measure, a red pen and a
"speed square".

Cutting The Legs:

I marked an 8' 2x4 at exactly 32" and 64". This board will give
me 3 legs, each just under 32".

Only for the legs: I align the cut so the middle of the blade
was on the line. (Normally I align the mark with one side of the
blade.)

Why? Because 8' 2x4's are normally exactly 96" long. (10', 12' etc. lumber is usually

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Building A Low-Cost Sturdy Work Bench From 2x4's And OSB http://www.hammerzone.com/archives/workshop/bench/belo...

about 1 inch longer than specified.) Since the saw blade is about 3/32" thick, I will lose a
significant amount of material due to the blade thickness. I don't care if the table legs
are not exactly 32" long, but I do care if they are not all the same length.

Maybe using one 10 foot long 2x4, cut into four legs exactly 30" long, would be the
smartest choice.

With the miter saw, cutting takes only a few minutes.

The lumber, after the cutting was done:

1. The side "stretchers", 45" long. (3" less than the overall
length.)
2. The legs, about 32" long.
The small pile on the
3. The end stretchers, 26" long.
left is the waste. Most of
this will eventually be
re-used.

Assembling The Side Frames:

The overall dimensions of the frame:

I marked the legs 6" above the floor.

The sides are laid on top of the legs,

forming a rectangle. The lower side
stretcher is aligned with the red line
mentioned above.

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Building A Low-Cost Sturdy Work Bench From 2x4's And OSB http://www.hammerzone.com/archives/workshop/bench/belo...

I arranged the pieces so the corners

were close to being square.

Then I drilled one hole at each corner.

I drove one 3" deck screw into each corner.

I checked the diagonal measurements.

They were within 1/8". Close, but not

good enough for me.

So I tapped the frame lightly, to shift it

a little. I held the lower part down with
my foot.

The squared-up side frame.

Then I drove in three more screws for

each joint.

Due to poor planning, I almost ran out

of 3" screws, so I used some 2-1/2"
Ardox (spiral) nails.

Assembling The Ends:

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Building A Low-Cost Sturdy Work Bench From 2x4's And OSB http://www.hammerzone.com/archives/workshop/bench/belo...

After the side frames were completed, I

turned them over and stood an end stretcher
upright, and then fastened it with deck
screws. I used the Speed Square to maintain
a right angle.

The side with two end stretchers attached.

The other side looked exactly the same.

Assembling The Two Halves:

I turned each half upside-down and placed

them together.

I used a Quick-Grip clamp to hold the

lumber while driving the deck screws.

Then I flipped the unit over and

connected the top components.

The completed frame.

Details: Note how the corners are joined.

This type of over-lapping 2x4 joint is quite
strong. Pre-drilling the holes helps prevent
splitting of the wood, which is common when
nailed or screwed near the end.

Installing The Shelves:

I placed the top piece of OSB on the

frame and attached it with 1-5/8" deck
screws. I spaced the screws about 8"
apart.

An aerial view.

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Building A Low-Cost Sturdy Work Bench From 2x4's And OSB http://www.hammerzone.com/archives/workshop/bench/belo...

The work bench with the top shelf attached.

The bottom shelf required a notch at each corner, to fit around the
legs.

The notches are a little bigger than 3" x 5".

Note the orientation of the notches: The 5"

dimension is along the long side of the panel.
I tilted the OSB panel to get it in place.
Fortunately it fit properly on the first try. In the
past I have had to cut the notches slightly larger
because the shelf would not fit the first time.
Cutting them 1/8" to 1/4" bigger seems to be a
fair compromise.

The bottom shelf was also attached with 1-5/8" deck screws.

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The completed work bench.

This is the 8th work bench I have built using this design. Every one has been a different
size, because each was made using materials on hand. Typically the dimensions of the
plywood shelves dictates the work bench size.

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Building A Low-Cost Sturdy Work Bench From 2x4's And OSB http://www.hammerzone.com/archives/workshop/bench/belo...

One has been narrow, only 18" wide

One has been quite long, 68" x 24", to support a wood lathe that weighs 150 pounds.
This bench has extra stretchers between the side rails.
Several have been made entirely of recycled lumber.
One bench used recycled 2x4's for the top, instead of plywood or OSB.
I routinely stand on these workbenches to reach lumber stored overhead. I find the
design to be the sturdiest I have seen, for the cost and level of simplicity.
I believe this structure is adequate for standing on because: 1.) The weight is
distributed on the equivalent of four studs, and 2.) 7/16" OSB is acceptable for roof
sheathing when the trusses are spaced 24" on center. The surface is a little springy, but
it will certainly hold the weight of a typical person.
On one of these benches I installed two electrical outlets. View that article.

workbench by howa Loi Scellier en 2011

wooden workbenches with tools good quality Baissez vos impôts - 8000€ avec Scellier !
and fair prices Etude perso & simulation

Tools Used: Materials Used:

Circular Saw Lumber, 2x4x8', (Qty: 5)

Cordless Drill/Driver OSB, About ½ Sheet
Hammer, Tape Measure Deck Screws, 3", 1-5/8"
4' Level or Chalk Line
Jig Saw (or Hand Saw)
Power Miter Saw (optional)

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Copyright © 1999, 2005 HammerZone.com

Written December 3, 1999

Revised January 4, 2005

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