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SN05216 - Knock Down Workbench PDF
SN05216 - Knock Down Workbench PDF
WORKBENCH
Workbench
That’s because the bench provides a solid, stable work-
surface like you’d expect from a bench. (There’s even a tool
tray underneath.) Then, once a job is completed, the bench
can be “knocked down” and stored in a compact box that
you carry like a suitcase. (See photo at right.)
The best thing about this
knock-down design is it makes
it easy to take the bench out
to the driveway or back yard,
or to a friend’s house to help
on a project. No matter where
you’re working, setting up the
bench only takes a minute.
Setup – To do this, start by
unlatching the lid on the box
and setting it aside. (The lid
doubles as the top of the work-
bench.) Then simply remove
the two stretchers and flip
up the sides of the bench, as
shown in photo A below.
The sides are hinged to the base, so you’ll need to
“spring” them apart a bit to fit the stretchers between
them (Photo B). These stretchers hook securely into the
sides with an ordinary set of bed rail fasteners. Then just
set the top down over the sides and pull it toward you to
lock it in place (Photo C).
Clamping Options – Once the bench is set up, there are
three different ways to clamp a workpiece to the benchtop.
That explains the holes and slots in the top as well as the
Turn a single sheet of plywood notches in the top of the stretchers. Note: For a closer look
and a few pieces of hardware into a at the different clamping options, turn to page 8.
portable workbench that “knocks down” Plywood – Just one more note. You won’t need a lot of
for compact storage. material to build this bench. The entire project is made
from a single sheet of 3⁄4" plywood. (I used pine plywood.)
A B C
Setup. It only takes a minute to set up the the top of the bench, the stretchers hook into the
workbench. After unlatching the top and setting it sides (Photo B). Then just fit the top down over the
aside, remove the stretchers and flip up the sides, sides of the bench and pull it toward you to “lock”
as shown in photo ‘A.’ To provide rigid support for it in place (Photo C).
1 WoodsmithPlans.com SN05216 ©2018 Cruz Bay Publishing, Inc. an Active Interest Media Company. All Rights Reserved.
I
TOP PANEL EXPLODED VIEW
!/4" x 2" OVERALL DIMENSIONS
STEEL PIN 32"W x 33#/4"H x 22"D
J &/8" x 2" K
LATCH HINGE
FRONT/BACK END FILLER STRIP #/4" x 3"
FILLER STRIP ALUMINUM
BAR
#6 x 1" Ph
WOODSCREW
BED RAIL
FASTENERS Hardware
H
STRETCHER
• (12) #8 x 1/2" Fh
Woodscrews
• (20) #8 x 11/2" Fh
Woodscrews
• (4) #8 x 2" Fh
Woodscrews
• (4) #10 x 1/2" Fh
Woodscrews
• (4) #6 x 1" Panhead
Woodscrews
• (1 Set) 4" Bed Rail
F Fasteners
H • (2) 1/4" x 2" Steel Pins
SHORT
SIDE STRETCHER • (2) 3/4" x 3" Aluminum
Bar (1/4" thick)
SPACER BLOCK • (1) 61/2" Drawer Pull
G • (1 Set) 7/8" x 2" Latch
Hinges
BACK E • (2) 11/2" x 18" Piano
A 1!/2" x 18" Hinges w/Screws
PIANO HINGE
TALL SIDE • (4) Draw Latches
w/SCREWS w/Screws
• (4) 3/4" Rubber Bumpers
C w/5/16"-18 x 11/4"-Long Stud
BOTTOM • (4) 5/16"-18 T-Nuts
CL
TOP
4!/2"
D 6!/2"
CORNER DRAWER
BLOCKS PULL
!/2"
DRAW
A B LATCH
#/4"
FRONT END
RUBBER BASE
BUMPER
DRAW LATCH
w/SCREWS
2 WoodsmithPlans.com SN05216 ©2018 Cruz Bay Publishing, Inc. an Active Interest Media Company. All Rights Reserved.
Base —————————— 1 D A
BACK
CORNER BLOCK (6!/2" x 32")
I began work by making the base of (1!/2" x 3")
#8 x 1!/2" Fh
the bench. As you can see in Figure WOODSCREW
2 AUXILIARY
FENCES
3 RIP
FENCE
CARPET
TAPE
NOTE: RUN
FRONT/BACK BOTTOM EDGE
ONLY OF ALL FRAME
PIECES AGAINST
RIP FENCE
GROOVE
DADO
BLADE
a. THICKNESS OF
#/4" PLYWOOD a. THICKNESS OF
3#/4"
#/4" PLYWOOD
A A
#/8" #/8"
3 WoodsmithPlans.com SN05216 ©2018 Cruz Bay Publishing, Inc. an Active Interest Media Company. All Rights Reserved.
But a drum sander can create
a scalloped edge if you’re not
4
careful. To prevent that, I used a
long, straight scrap piece as a fence
(Figure 4). With the “feet” of the
workpiece riding against the fence, 3" DRUM
SANDER
it’s easy to sand a straight edge.
To sand the entire thickness FENCE NOTE: CUT
of the edge, you’ll HOLE IN AUXILIARY
TABLE TO ACCEPT
need to attach an aux- DRUM SANDER
iliary table to the drill FRONT/ AUXILIARY TABLE
BACK
press and cut a hole in
NOTE: FEED WORKPIECE
it to accept the drum sander. FROM LEFT TO RIGHT
Then, after notching the fence to fit
a. NOTCH DETAIL b. NOTCH DETAIL
around the drum sander, position it
to sand to the desired depth and FRONT/BACK END
clamp the fence in place.
Now turn on the drill press, and
push the workpiece into the drum 2!/4" 2!/4"
1!/2" 1!/2"
RADIUS RADIUS
sander until it contacts the fence.
2&/8"
The idea is to start at the right 3!/4"
#/8" BRAD
a. POINT BIT
3"
1!/2"
NOTE: D
BLANK FOR CORNER
BLOCKS IS GLUED UP CORNER
FROM TWO PIECES BLOCKS CORNER
OF #/4" PLYWOOD BLOCK
4 WoodsmithPlans.com SN05216 ©2018 Cruz Bay Publishing, Inc. an Active Interest Media Company. All Rights Reserved.
Supports —————
SLOTTED
HOOKED
BED RAIL
FASTENER
BED RAIL
FASTENER
This workbench is designed with a
simple system of interlocking parts
that provide solid support for the
F #8 x 1!/2" Fh
top. As you can see in Figure 7, it WOODSCREW
consists of two hinged sides con- SHORT
SIDE H
nected by a pair of stretchers. #4 x %/8 Fh STRETCHER
To prevent the bench from WOODSCREW
5 WoodsmithPlans.com SN05216 ©2018 Cruz Bay Publishing, Inc. an Active Interest Media Company. All Rights Reserved.
The reason has to do with the hooks
on the mating fastener. To lock the
9 AUXILIARY
FENCE
two parts of the fastener together,
the hooks have to fit straight into
the slots and then slide downward.
Increasing the length of the mor-
tise provides the clearance that’s
needed for the hooks. %/8" CUT !/8"-DEEP
MORTISE
FORSTNER
After laying out the deep mor- BIT 4!/8" LONG
tises, chuck a smaller bit in the
SIDE
drill press and use the same proce-
FIRST: DRILL OVERLAPPING
dure as before to cut two pockets a. HOLES
(Figure 9c). Then screw the fas-
teners in place. SECOND: PARE OFF
Install Sides – Now you’re WASTE WITH CHISEL
10 WASTE
NOTE: STRETCHERS
ARE MADE FROM 11
#/4" PLYWOOD
1!/2" RADIUS
2!/4"
2#/4"
STRETCHER
H DRILL
STRETCHER !/2" COUNTERBORE
(10" x 29") !/8" DEEP AUXILIARY
FENCE
DADO
a. SIDE
BLADE
SLOTTED
a.
HOOKED
FASTENER FASTENER
NOTE: CUT NOTCH STRETCHER
2#/4" FROM TOP
HOOKED EDGE OF STRETCHER
BED RAIL THICKNESS
FASTENER OF
3!/4" 4!/8" BED RAIL
POCKET FASTENER
FOR NIB #8 x 1!/2" Fh
NOTE: WOODSCREW
MAKE TWO
STRETCHERS WASTE
STRETCHER
6 WoodsmithPlans.com SN05216 ©2018 Cruz Bay Publishing, Inc. an Active Interest Media Company. All Rights Reserved.
Top ——————————
12
TOP
The top of the workbench
that’s shown in Figure 12
has two main jobs. It creates
LATCH
a solid worksurface. Plus it HINGE
serves as a lid for the base METAL PIN
when you knock down the
bench for storage STRETCHER
But the handiest thing about SIDE
this benchtop is it provides
three different ways to clamp a
workpiece to the bench. (Refer
to the photos on page 8.)
Built-Up Top – To
increase the thickness of the
top, it’s “built up” from two length of the top panel. To fit over strips are aligned flush with the
layers of 3⁄4" plywood. The the sides of the bench, you’ll need to notch and then glued in place.
{ A simple two- upper layer is formed by a cut a notch near each end of these Slots for Clamps – With the filler
part system is top panel (I) that’s sized to fit strips. Then just glue them in place. strips in place, the next step is to cut
used to fasten flush with the base (Figure 13). Next, I added two narrow end four slots in the top. Each slot forms
the top to the And the lower layer is made up of filler strips (K). They’re ripped an opening for a bar clamp that lets
bench. Metal several smaller filler strips. to width so when they’re flush you clamp work near the middle of
pins in the top Filler Strips – These strips with the outside edge of the top, the benchtop. A quick way to cut
fit under the create a long, narrow recess they align with the notch in the each slot is to drill a small starter
aluminum bars underneath the top which fits front/back strips. As for length, hole and then remove the rest of the
on the sides down over the sides of the bench. it’s just a matter of cutting them waste with a sabre saw (Figure 14).
(upper photo). Plus they provide the thickness to fit the opening. Bench Dog Holes – In addition
And spring- that’s needed to hold a set of bench After gluing on the end strips, to the slots, I drilled a number of
loaded latches dogs. (For more about the bench I added two inside filler strips holes in the top to hold the bench
lock the top in dogs I used, turn to page 9.) (L). To provide clearance for the dogs. Since the top is quite large,
place (lower The front and back filler strips stretchers, these strips are shorter I clamped an auxiliary table to my
photo). (J) are simply cut to match the than the end strips. Here again, the drill press to support it (Figure 15).
J
FRONT FILLER
STRIP
15 3"
AUXILIARY
TABLE
AND FENCE
(3#/4" x 32") K
END FILLER #/4"
STRIP FORSTNER 4"
BIT 4"
BOTTOM VIEW CL (#/4" x 14!/2")
#/4" 2!/2" END FILLER STRIP
4"
TOP 4"
!#/16" FRONT INSIDE BACK
FILLER FILLER FILLER 4"
STRIP STRIP STRIP NOTE:
DRILL TWENTY
#/4"-DIA. HOLES
7 WoodsmithPlans.com SN05216 ©2018 Cruz Bay Publishing, Inc. an Active Interest Media Company. All Rights Reserved.
a.
LATCH
16 BACK
2#/8" PIN
(!/4" x 2"
17 HINGE
a. TOP
SIDE &/8" x 2"
BAR LATCH
1#/16" NOTE: HINGE
DRILL !/4" HOLE DRILL
2!/8" DEEP TO #/16" HOLE,
HOLD PIN SIDE !/2" DEEP
METAL #6 x 1" Ph
PIN WOODSCREW
SIDE
It’s also a good idea to clamp a a dimple in the side. Then simply page 2.) These latches hold the top
fence to the table to make sure remove the top and drill the holes and base together when you knock
the holes are located the same dis- for the latch pins. the bench down for storage.
tance in from the edge. Then lay Draw Latches – In addition to Handle – All that’s left is to add
out and drill the holes. the latch hinges, I also installed a handle to make it easy to carry
Locking System – At this point, two draw latches on each end of the the bench. It’s centered on the front
the top is almost complete. But bench. (Refer to Exploded View on of the base and screwed in place.
before setting it on the bench, I
added a simple, two-part system
that “locks” it securely in place.
If you look at the photos on page
7, you can see how this works. In
back, the top is held in place with
two metal pins that fit under the
aluminum bars installed earlier. In
front, it’s secured with a couple of
spring-loaded latch hinges. < Pipe Clamps. To hold
Install Pins – As you can see in a workpiece against the
Figure 16, each pin is a short piece edge of the bench, slip pipe
of 1⁄4"-dia. metal rod. The pin fits clamps through the notches
into a hole drilled in the end of the at the top of the stretchers.
back filler strip (Figure 16a). After
applying a small amount of epoxy in
the hole, tap in the pin and clean up
any excess that squeezes out.
Latch Hinges – The second part
of the locking system is a pair of
latch hinges. Each latch hinge has a < Bar Clamps. Fit the
spring-loaded pin that fits into a hole head of a bar clamp down
in the side of the bench (Figure 17). through one of the slots in
(For a source of latch hinges, refer the top to clamp work near
to page 9.) An easy way to locate the the middle of the benchtop.
holes for the spring-loaded pins is
to screw the latch hinge to the top,
as shown in Figure 17a. Note: The
latch hinges I purchased didn’t have
mounting holes, so I had to drill a
couple of holes in each one.
Now lower the top down over
the sides and pull it toward you so < Bench Dogs. Using one
the metal pins in back slip under (or more) pairs of bench dogs
the aluminum bars. After centering lets you hold work tightly
the top from front to back, tap each against the top without
of the spring-loaded pins to make clamps getting in the way.
8 WoodsmithPlans.com SN05216 ©2018 Cruz Bay Publishing, Inc. an Active Interest Media Company. All Rights Reserved.
MAIL Project Sources
ORDER
SOURCES The Knock-Down Workbench
makes an ideal, general-purpose
Lee Valley
800-871-8158 bench for working on projects
leevalley.com around the house. Plus it “knocks
down” for storage.
McMaster-Carr To assemble the workbench (and
630-600-3600
mcmaster.com take it apart), we used the same
type of hardware that’s used to join
the rails on a bed to the headboard
and footboard. These 4" bed rail fas-
teners are available in sets of four
from the sources listed at left.
There are also several other
pieces of hardware that you’ll need.
The rubber bumpers (Part No.
9546K18) that act as the “feet” of the
bench, and the latch hinges (Part
No. 1305A38) that secure the top
are available from McMaster-Carr.
To clamp a workpiece against the
benchtop, we purchased two pairs
of bench dogs from Lee Valley called
Bench Pups (05G04.04) and Wonder
Pups (05G10.02).
Manufacturers and retailers will
periodically redesign or discon-
tinue some of their items. So you’ll
want to gather all the hardware,
supplies, and tools you need before
you get started. It’s easy to adjust
dimensions or drill different-sized
holes to suit your hardware.
9 WoodsmithPlans.com SN05216 ©2018 Cruz Bay Publishing, Inc. an Active Interest Media Company. All Rights Reserved.