This winter was a fairly productive one for me because I completed two major projects: a doll wardrobe and (drum roll, please) my new workbench. This workbench has been a long time coming:
- In 2002, I started planning to build a workbench. I bought some supplies and began working on a base, but I had to turn my attention to other projects and I never came back to it. That base was eventually scrapped.
- In 2004, I built a fully enclosed cabinet base for a Shaker-style workbench. I then decided I didn’t like that style of bench, so I converted the cabinet into a miter saw stand instead.
- In 2007, I built the actual base for this bench in fits and starts while I was working on another project.
- In 2010, I finally completed the overall bench.
Wow… eight years. That must be a record of some sort. There just always seemed to be some other project that was higher priority. For the past eight years, I’ve used a sheet of plywood on some sawhorses and (more recently) my table saw outfeed table as a bench. Both solutions were less than ideal.
My workbench does not look like a piece of fine furniture. It’s not made out of expensive lumber, it has no inlays or decorations, and it’s not named after a long-dead Frenchman. Instead, I built a workhorse: stout, simple, and spacious.
Both the top and the base are solid douglas fir. I used a knockdown base design; the whole thing is bolted together using lag bolts. Someday I might move; if that happens, I’ll be able to 
break this monster down and bring it up out of my basement. In the picture, you can see how the base is constructed and how the top is attached. The top stretcher sits in a bridle joint at the top of the legs and is secured with lag bolts. The top is attached with a single lag screw in the center, which allows it to expand and contract freely.
The bench top is 24” deep, 84” long, and 3” thick. Flattening the top with handplanes was surprisingly easy… even for a newb like me; it only took me about 90 minutes from start to finish. I used a jack plane to knock down the high spots 
first. Then I gave my jointer plane a workout by planing across the grain, then diagonally, and finally with the grain to clean things up. I ended up with a few areas of tearout, but I didn’t spend too much time worrying about it since this is a benchtop, not a dining room table.
I decided to use 3/4” round dog holes because they are more versatile than square dog holes. I spaced the holes 3.5” inches apart. I used Glen Huey’s router jig method for drilling the holes: a plunge router, a simple alignment jig, and a 3/4” upcut spiral bit are used to drill as deeply as possible. I then finished the holes off with a 3/4” spade bit.
My front vise is a Record 52 1/2ED, and my end vise is a Record 52. I bought both of these vises back in 2002 when Record was 
still in business, and they’ve been languishing in their boxes ever since. It felt great to finally get them bolted to a benchtop.
Even though it was a lot of hard work and heavy lifting, I’m glad I built my own bench. I enjoy working on it just a little bit more knowing that I built it myself… and I guess that’s something you can’t put a price on.
Congrats, Dave! I hope to join these ranks soon, but it might take just as long for me to finish. I’m only 5 months out from having bought materials for it!
Very nice! Makes me feel better about my slow progress. I’m starting into year 3 of my workbench project. Mine is also solid dougy fir. I’m hoping to finish this summer.
That looks like a very sturdy bench; well done!
Interesting to see that you’ve made it entirely knock-down, when you probably could have glued the end frames together (but yes, that still makes it easier to move and also allows you to alter things in future).
I built my bench last summer after a good twelve-months of thinking and I’d had to go back a couple of times to “revise” things…
Do you think you’ll be happy with this one or will you be making another in ten years?
A lot of woodworkers are like that, apparently.
Olly.
“it’s not named after some long dead frenchman”
I’m still snickering about that. Nice job!
Great looking bench! My media center took much longer than I wanted, but it was worth the wait once it was done. The Record vises are a nice touch. I sure like mine.
Nice bench! I’m in the planning stage of building a bench and I may steal some of your ideas.
I’m going to use an old solid wood fire door for the top temporarily, until I have the time and tools to make one like yours.
Glad to see you back in the shop! Podcast sometime soon describin’ the build?
Dave,
great bench. I’m glad to see you checked one off of the To Do list.
Any plans on getting back to Podcasting? I have hours to listen in the car and no time to watch at home. With everyone else in woodworking focusing so much on video, I really miss your great audio.
Keep up the great work.
I second Dyami’s comments in that its nice to see you get that bench completed. Hope to hear some podcasts coming?
Congrats.
IT LOOKS GREAT ! Some people build the bigest thing possable insted of what works for them and there shop.
Great looking bench. I second (or third, or forth, or fifth) the comment regarding your podcasts. I really miss them, you do a great job.
Sorry to sound repetitive but I do like the look of your bench, very well made.
Nice looking bench. As much as I hate to say it, but I think the long dead frenchman would want to know if you could move the bench away from the wall. Ideally you want 360 access to what you are working on. I personally don’t have the room, but just a thought.
Keep up the good work.
yaakov…..
Artisan’s Call
Hey Dave,
Looks great! I just finished listening to one of your very first podcasts (for the second time) from like early 2008 on benches. I hope that it is as functional as you want it to be.
Hi, Dave–I’ve been listening to all of your podcast episodes, and enjoying them very much. Your workbench project is very timely for me, because I’m just beginning to set up a shop in my garage, and a workbench will be one of my first projects.
Years ago when we replaced some furniture in our home, I saved parts of an old couch that was constructed with 2″ thick veneered chipboard, so the back (2″x23″x79″) will serve as my bench top. Maybe one day I’ll replace it with a solid wood top of some sort, but it’s a start.
Haven’t seen anything new from you for a while–I hope all is well.
Blessings, Doug
Congrats! That is one sweet workbench. It’ll last you a lifetime.