How to build a workbench.

One of the great ironies of tools and their use is that the absolute best area to work on is a workbench — a high, solid, well lit, structure on which to cut and vise and connect and create. No question. And in order to have the right workbench for you, you’ll need to build one. And in order to build one, you’ll need a workbench. Well … This isn’t completely true. You can build one, without one. But later on when you’re using the bench and you have it exactly the way you like it, you’ll realize that it would have been so much easier to build it if you had it before. Now, in this world of mass produced everything, why would you want to build a workbench? Great question. And there are about a zillion reasons why — well, that’s also not true. There are five. Five reasons why— but they are five pretty good reasons.

1. Quality. Most workbenches are cheap, mass-produced structures. You can get workbench and workbench kits — where you add your own lumber — everywhere from Lowes to CVS, — yup, I have seen workbench’s at CVS on Father’s Day. And 90% of these are light, poorly designed structures that will not work well with your home, garage, or the type of projects you will be working on. The remaining 10% that are fairly well designed and constructed are not designed specifically for you.
2. Cost. For a fraction of the cost of the most expensive pre built workbench out there, you can build one yourself — actually, less than that, you can get a high end workbench for almost $1,000 and the lumber for that would be around $100.
3. Designed specifically for you. What type of work are you going to be doing and how do you like to do it? Because a workbench for wood carving is going to be different than one for repairing old radios. Are there enough outlets? Is there a place for your coffee pot and for all the stuff you like to have around you?
4. Designed specifically for your location. There are many times that you could find the ultimate workbench — if your garage was bigger. Or your basement had more light. Or you had more space in the shed. You need to design your bench for the real estate it will take up as well as the space you don’t. In fact there are many, fold down workbenches that work great.
5. Sense of pride. There is something about building — anything, but there is great irony in having a structure to build things on, that you didn’t build.

HOW TO BUILD A WORKBENCH

1. Location. Decide where the bench will go — which is actually more important than the design itself. Walk out where it will sit, look all around it, is there enough light, enough storage space? Is it easy to get material in and out? — a bench to finally build that canoe may not work well in your basement where the finished product cant get back out.
2. Overall design. There are some great sites online that offer overall workbench plans and here is the best one I found that incorporates many of them http://freebies.about.com/od/free-plans/tp/free-workbench-plans.htm Choose an overall plan and then look at the areas you want to personalize such as height of the bench. And if you don’t like any of these, just draw out what you like and add in the two important aspects; power and light. You will want to attach at least one power strip right to the workbench for power needs and you will need at least one flexible lamp for additional light.
3. Simpson ties. If there is a magic trick in building a solid, rugged workbench, it’s Simpson ties. Simpson is a company that was founded by a man named Barclay Simpson — who just passed away this past November at the age of 93 — that manufactures joist hangers, angles and a bunch of other stuff that strengthen structures. And since a workbench is not a table but a solid work structure that you can vice something to and saw or hammer, you want it to be solid. By using Simpson ties for the corners of your bench and where the lumber fits together, your bench will be rock solid.
4. Overdesign for material. Like any project, once you finalize you design and make your materials list, add about 25% more of everything you’ll think you’ll need. This is an overall handyman trick that works, because it is far better to make one trip back to Lowes when you are done to return what you don’t need, then it is to make the six extra trips for what your forgot. So buy more than you need and return it.
5. Take your time. As you get going you may want to make changes or add in new pieces of jewelry to the project. No rush. Take your time.

… and let us know how it went. Please post photos of your workbench — or of any project you are working on — at the 543skills forum — http://543skills.com/forumpress/