BUILDING A WORKBENCH
Michael Holigan: Every handyman needs a quality workbench.
Al Carrell: And we're going to show you how to build one for probably about 100 bucks.
MH: Here's what it will look like. It's a functional beauty with lots of storage and workspace that will really come in handy. You can download a complete materials list and plans from the Project Plan section of our web site.
AC: We're going to start by building the back wall.
MH: Three 2x4's, each three-foot in length, give us a solid framework for the back wall. Two and a half-inch wood screws guarantee this bench is going to stand up for years of use. Now we measure the inside diameter of the framework, so we can make a storage shelf - 67 1/2. We mark off a 2x8 and cut it to length. Then we position it about 18 inches down from the top of the back wall.
AC: Now, we're going to flip it over so we can attach the pegboard to the back.
MH: A four-foot by eight-foot sheet of quarter inch pegboard provides a great place to hang tools.
AC: We're going to attach the pegboard to the back before we cut it off. It'll be more stable that way.
MH: Al, let's pop a line here.
AC: All right. We're good here.
MH: Good, pull it. We cut the pegboard down to six feet in length. Once it's cut down to size, it's on to the bottom half of the workbench.
AC: Remember how long this is?
MH: Sixty-seven and a half is what it should be.
AC: That's exactly right. There's the halfway mark right there.
MH: Thirty-three and three-quarters. So that puts our stud at 33. This center stud will run the remaining length of our bench serving as the divider for our two middle shelves and as center support for our worktop. We use three 2x6's to create a U-shape frame that will actually support the worktop.
AC: You going to screw it in from the top or the side?
MH: From the side.
AC: Okay.
MH: Now it's time to attach the front legs.
AC: You want me to hold it?
MH: Yeah.
AC: Little dance. Do-si-do. Help, I'm trapped!
MH: We stand the frame upright to place it in position. Yeah, that's going to work.
AC: It's beginning to look a little like a workshop. Seventy-five, right on the nose.
MH: Good. We cut a 3/4 inch sheet of plywood to size for the worktop.
AC: Now we need to get these ends flushed up over here. How's that down there?
MH: Looks good down here.
AC: We're going to have to cut out notches in here. So, that's what we're making marks for, so that this will fit back against the pegboard back here. Well, let's flip this baby over and see if it fits. Fits like a glove!
MH: Now it's time to build two shelves - one for this side of the bench and one for that side. They're actually going to be at different heights and we think it's going to be easier if we just build the frame, the box itself, up top and then we'll just slide it in and screw it in place. We use four 2x4's to form a rectangle. Then we attach a plywood shelf on top. The shelf slides right into place and is secured with screws. Another set of 2x4's, attached along the back of the worktop, function as a protective backsplash so we don't knock a hole in our pegboard when working on projects.
AC: Well Michael, if we can learn how to use all these tools we'll be great, won't we?
MH: Yeah. Then we can get one of your books. If you'd like the plans to build this workbench you can find them online in the Project Plan section of our web site at YourNewHouse.com.
AC: It was a really easy thing to do and it cost about 100 bucks.
Episode 65 1997 - 98 Season
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