A solid workbench with a thick top and sturdy base. This project combines multiple joinery techniques and results in a tool that will serve you for decades.
| PIECE | QUANTITY | DIMENSIONS |
|---|---|---|
| Top laminations | 20 | 1-1/2" x 3-1/2" x 72" |
| Legs | 4 | 3-1/2" x 3-1/2" x 34" |
| Long stretchers | 2 | 1-1/2" x 3-1/2" x 60" |
| Short stretchers | 2 | 1-1/2" x 3-1/2" x 18" |
Select the straightest 2x4s for the top. Reject any with large knots or warps.
Joint one edge of each 2x4 perfectly straight.
Glue and clamp 2x4s edge-to-edge in groups of 5. You'll create 4 sub-assemblies.
Once dry, flatten one face of each sub-assembly with a hand plane or sander.
Glue the four sub-assemblies together to create the full top.
Flatten the top surface with a belt sander or hand plane. It should be dead flat.
Cut legs from 4x4 posts to 34 inches (or desired height minus top thickness).
Assemble base using half-lap joints where stretchers meet legs.
Secure all joints with lag screws for maximum strength.
Attach top to base with screws through stretchers into underside of top.
Install bench vise if desired.
Apply a durable finish like boiled linseed oil.
A workbench doesn't need a fancy finish. Boiled linseed oil or Danish oil provides protection while being easy to repair. Apply liberally, let soak in, wipe off excess. Reapply annually or as needed.