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power tool
bench
modern
WoodsmithPlans.com SN13128
adjustable
shelf increases
storage capacity
hardwood
foot pad fits
inside leg
aluminum rails
support storage
cabinet
handle made from
aluminum angle &
hardwood
rack stores
chargers and
keeps cords neatly
organized
square aluminum
tubing makes for
strong yet light legs
NOTE: Rack
and totes made
from Hardwood
HARDWOOD
totes feature
box joints for
strength
removable totes
provide storage for
power tools
Legs (4)
3 x 3 - 34 Square Alum. Tube
Rails (4)
112 x 112 - 29 Alum. Angle
Sides (2)
17 x 2914 - 34 Ply.
3 x 1 - 29
Cleats (4)
4
3 x 3 - 3
Foot Pads (4)
4
Back (1)
20 x 60 - 34 Ply.
Bottom (1)
30 x 5914 - 34 Ply.
Lower Rail (1)
612 x 60 - 34 Ply.
Inner Side (1)
29 x 11 - 34 Ply.
Divider (1)
29 x 1314 - 34 Ply.
3 x 11 - 131
Stiles (3)
4
2
2
3 x 2 - 60
Upper Rail (1)
4
3 x 2 - 591
Mounting Cleats (2)
4
4
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
Shelf (1)
1834 x 2814 - 34 Ply.
3 x 3 - 183
Shelf Edging (1)
4
4
4
3 x 13 - 381
Stop (1)
4
4
2
3 x 3 - 28 Alum. Angle
Guides (6)
4
4
1 x 81 - 28
Tote Sides (6)
2
2
1 x 81 - 12
Tote Ends (6)
2
2
Tote Bottoms (3)
1112 x 2712 - 34 Ply.
3 x 1 - 11
Tote Cleats (6)
4
1
1
Handle Bases (6) 1 2 x 1 2 - 5 Alum. Angle
3 x 1 - 5
Handle Caps (6)
4
Top (1)
112 x 36 - 72
3 x 8 -25
Rack Shelf (1)
4
3 x 7 -25
Rack Back (1)
4
WoodsmithPlans.com SN13128
AA Braces (2)
BB Cord Rail (1)
3
4
3
4
x2-4
x 2 - 25
FIGURE
MOUNTED FLUSH TO
TOP OF LEGS
RAIL
LEG
a.
SIDE VIEW
FRONT VIEW
RAIL
CLEAT
CLEAT
12
!/4
!/4
SIDE
#/4
SIDE
C
SIDE
CLEAT
NOTE: RAILS
LEG
CLEAT
RAIL
RAIL
b.
D
CLEAT
SIDE
LEG
#8 x 1" Rh
WOODSCREW
!/4
building a solid
RAIL
Bench
RAIL
CLEAT
LEG
SIDE
WoodsmithPlans.com SN13128
c.
CLEAT
TOP VIEW
SIDE VIEW
FOOT PAD
PAD
E FOOT
(#/4" x 3" - 3")
!/8
!/4
!/8
!/2
FIGURE
F
BACK
SIDE
G
BOTTOM
a.
SIDE
VIEW
!/4
BOTTOM
BACK
H
LOWER RAIL
b.
!/4
LOWER
RAIL
5#/4
CLEAT
SIDE
!/4
SIDE
RAIL
19#/4
!/4
BOTTOM
LOWER
RAIL
FIGURE
#/4
BACK
a.
FRONT VIEW
19%/8
#/4
MOUNTING
CLEAT
NOTE: HOLES
FOR SHELF PINS
ARE !/4"-DIA.
DIVIDER
!/4
L
UPPER RAIL
K STILE
(#/4" x 1!/2" - 13!/2")
FRONT
VIEW
J
DIVIDER
M
MOUNTING
CLEAT
c.
!/4
BACK
b.
SIDE VIEW
c.
CL
CLEAT
BOTTOM
!/4
#/8
!/4
TOP #/8
VIEW
UPPER
RAIL
20
WoodsmithPlans.com SN13128
3!/4
STILE
Details
You can turn your attention now
to adding storage, a top, and a
battery charging station to your
bench. Three roomy removable
totes fit inside the bench to hold a
variety of power tools. An adjustable shelf is ideal for accessories.
The thick hardwood top makes
for a lot of working space. Finally,
the charging station keeps chargers and batteries organized and
easy to access whenever needed.
Paint. Before getting started
though, remove the leg and rail
assemblies to paint the cabinet. I
primed it first and then sprayed
on a couple coats of paint.
Shelf. Theres not a lot to do
when it comes to the adjustable
shelf. Its cut to size, and edging
is applied to the front, as you can
see in Figure 4.
Guides. After re-attaching the
leg assemblies, install the drawer
stop and guides (Figure 4). Spacers help keep them square and
parallel as you fasten them.
Strong & Sturdy Totes. The
trio of totes is designed from
the ground up to hold a lot of
tools (photo above). The 34" plywood bottom combined with
FIGURE
NOTE:
DISASSEMBLE
LEG AND RAIL
ASSEMBLY TO
PAINT CABINET
STOP
SHELF
a.
FRONT
VIEW
!/8
b.
12
#6 x !/2" Fh
WOODSCREW
EDGING
O
EDGING
SHELF
GUIDE
Q
GUIDE
WoodsmithPlans.com SN13128
SHELF
PIN
SIDE
VIEW
2013 August Home Publishing Co. All Rights Reserved.
a.
TOTE SIDE
TOTE END
FIGURE
NOTE:
!&/32
!/2
!/4
b.
!/2
GROOVES
FOR TOTE
BOTTOM
SHOULD
ALIGN
WITH
EDGE OF
NOTCH IN
BOX
JOINT
!/4
TOTE
BOTTOM
!/4
c.
SIDE VIEW
TOTE
CLEAT
HANDLE
BASE
#8 x 1" Fh
WOODSCREW
TOTE
END
TOTE
BOTTOM
FRONT
VIEW
V
HANDLE
S
TOTE END
!/2
NOTE: SEE
SHOP
SHORT CUTS
ON PAGE 7
FOR MORE
ON MAKING
HANDLE
X
TOP
MOUNTING
CLEAT
1" DIA.
1!/2
FIGURE
a.
TOTE
END
SIDE
VIEW
R
TOTE SIDE
TOTE CLEAT U
(#/4" x 1" - 11")
d.
HANDLE CAP
TOTE
SIDE
GUIDE
!/4
TOTE BOTTOM
1!/2
#/8
NOTE: TOP OVERHANGS
FRONT OF BENCH #/8
BY 3" AND
IS CENTERED SIDE TO SIDE
9
CL
TOP
VIEW
RACK SHELF
TOP
RACK SHELF
LEG
1!/2
BRACE
TOP
VIEW
9
RACK SHELF
2&/8
45
POWER
STRIP
RACK
BACK
STRIP
b. POWER
CL
#/8
BB
CORD RAIL
CL
WoodsmithPlans.com SN13128
CORD RAIL
2!/2
Z
RACK BACK
c.
1!/2
AA
AA
BRACE
RACK SHELF
SIDE
VIEW
1" DIA.
#/8
NOTE: USE
#8 x 1!/4" Fh
WOODSCREWS
#8 x 1!/2" Fh
WOODSCREW
#/8
2
2&/8
!/4
1" DIA.
TOP VIEW
d.
tips from
Our Shop
Shop
Short
Cuts
The tote handles for the workbench are made from a section
of aluminum angle with a hardwood cap. The drawings below
step you through the process of
making the handles.
To make the handle caps, start
with extra-wide blanks (Figure
1). After routing a roundover on
both ends, I stepped over to the
table saw to cut the slots that fit
over the aluminum angle.
Tote Handles
Figure 2 shows how I used a
saw blade to cut a slot
centered on each long-grain edge
of the blank. The next step in
making the caps is to rip them
from the blanks and then round
over the remaining edges, as
illustrated in Figure 3.
Now for a little metal work. I
cut the aluminum angle to length
and rounded off two of the corners of one leg with a file, as you
1 "-kerf
8
END
VIEW
a.
a.
TABLE SAW
FENCE
END
VIEW
HANDLE
BLANK
HANDLE
BLANK
!/4" ROUNDOVER
BIT
CL
%/8
3
ROUTER
TABLE FENCE
FIGURE
1!/2" x 5"
ALUMINUM
ANGLE
HANDLE
CAP
PUSH
BLOCK
!/2"
RAD.
a.
PUSH
BLOCK
a.
END VIEW
COUNTERSINK
FOR #8
WOODSCREW
!/4" ROUNDOVER
BIT
END VIEW
7
WoodsmithPlans.com SN13128
#6 x !/2" Fh
WOODSCREW
Legs (4)
3 x 3 - 34 Square Alum. Tube
Rails (4)
112 x 112 - 29 Alum. Angle
Sides (2)
17 x 2914 - 34 Ply.
3 x 1 - 29
Cleats (4)
4
3 x 3 - 3
Foot Pads (4)
4
Back (1)
20 x 60 - 34 Ply.
Bottom (1)
30 x 5914 - 34 Ply.
Lower Rail (1)
612 x 60 - 34 Ply.
Inner Side (1)
29 x 11 - 34 Ply.
Divider (1)
29 x 1314 - 34 Ply.
3 x 11 - 131
Stiles (3)
4
2
2
3 x 2 - 60
Upper Rail (1)
4
3 x 2 - 591
Mounting Cleats (2)
4
4
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
3 x 2 - 4
Shelf (1)
1834 x 2814 - 34 Ply. AA Braces (2)
4
3 x 3 - 183
3 x 2 - 25
Shelf Edging (1)
BB Cord Rail (1)
4
4
4
4
3 x 13 - 381
Stop (1)
4
4
2
3 x 3 - 28 Alum. Angle
(16) 12-14 x 34" Self-Drilling Screws
Guides (6)
4
4
1 x 81 - 28
Tote Sides (6)
(20) #8 x 1" Rh Woodscrews
2
2
1 x 81 - 12
(12) #8 x 1" Fh Woodscrews
Tote Ends (6)
2
2
Tote Bottoms (3)
1112 x 2712 - 34 Ply. (30) #6 x 12" Fh Woodscrews
3 x 1 - 11
Tote Cleats (6)
(10) #8 x 112" Fh Woodscrews
4
Handle Bases (6) 112 x 112 - 5 Alum. Angle (14) #8 x 114" Fh Woodscrews
3 x 1 - 5
Handle Caps (6)
(1) Power Strip
4
1
Top (1)
1 2 x 36 - 72 (2) #8 x 34" Rh Woodscrews
3 x 8 - 25
Rack Shelf (1)
(6) 14"-dia. Shelf Pins
4
3 x 7 - 25
Rack Back (1)
4
Cutting Diagram
#/4" x 8!/2" - 96" POPLAR (5.7 Bd. Ft.)
D
D
L
M
M
BB
W
AA
AA
1!/2" x 7!/2" - 72" ASH (FIVE BOARDS @ 7.5 Bd. Ft. EACH)
X
WoodsmithPlans.com SN13128
Cutting Diagram
cont.
1!/2" x 7!/2" - 7
48" x 96" - #/4" PLYWOOD
WoodsmithPlans.com SN13128
MAIL
ORDER
SOURCES
Woodsmith Store
800-444-7527
McMaster-Carr
630-833-0300
mcmaster.com
10
Project Sources
As far as hardware goes for the modern power tool bench, youll need 3"
square aluminum tube (88875K73),
12-14 x 34" screws (90064A580), 34"
aluminum angle (88805K44), and 112"
aluminum angle (8982K134). All of
these can be found at McMaster-Carr.
The cabinet of the bench was painted with Benjamin-Moore Aura satin
paint, Fair Isle Blue color. The benchtop, totes, and shelf were finished
with a wipe-on oil finish.
WoodsmithPlans.com SN13128