Small Workshop Workbench Build - Part 1

[Music] hi and welcome to Matt's Workshop in this short video series I'd like to present to you a project that I've been working on in the last few months it actually started during the pandemic and I'm still working on it today so it took me a few months of Designing a mycad software to come up with something that I liked followed by several months of building and shooting everything to be able to produce this video if you enjoyed that kind of content please follow along and don't forget to like And subscribe first I'm going to present to you the different features that I have integrated into the workbench so as you see it you see the workbench from the let's say the power tool side perspective so the first tool that I have integrated is the table saw the table saw I own is the DeWalt DW 745 just on the left you have the router lift then both the table saw and the router will be sharing the common softens that you see here which is a custom design [Music] the saw box will contain the table saw itself and will give access to it when we want to remove it from the workbench and both power tools will also be controlled by a common control panel on which there is two different safety switches on the opposite side of the control panel I have the right panel that is just meant to receive some tools that I can hang up on some hooks or things like that and just beside it you can see the right toolbox if you look at the workbench from what I call the work holding side perspective you can see that we have another toolbox which I call the left toolbox we also have the router box that contains the router lift itself then there's the vent collector system that I can use to collect the dust from either machine and now more specifically on the work holding features we have first the phase bytes then we have the inset Vice which is a little bit like a tail vise and then I have a dead man and several different dog holes in various positions across the workbench I also had several other constraints I wanted to consider so first I wanted the workbench to be on retractable casters I wanted it to be very heavy I wanted to be at a height of about 38 inches which I find comfortable and I wanted to be as narrow as possible as long as it accommodates the the tools that I needed I wanted it to be about 1500 millimeters long I wanted one single 120 volt power cord and I wanted every possible voids to be turned as much as possible at least into some sort of storage to integrate the table saw I did not want to have to cut the front of the frame to keep its rigidity so I decided to go with a design where the table saw would be held in the box that could lower down and there will be a drawer that you could extend out of it to remove the table saw comfortably [Music] you can see some renders of the frame here as we move on to the beginning of the build the first step is to cut all the pieces to their rough sizes and to do that I use a combination of the track saw and the table saw [Music] [Music] the first component I'm going to build are the legs and pretty much every sub component of the legs are made the same way so I have different raw material that were cut with and they have a little bit of extra length so now as you see here I just make sure that everything is square and cut them to the length that I need [Music] [Music] now that I have all the pieces cut to length I can start to work on the different cuts I need to to do in every single component the workbench is going to be built using some joinery and I found it much easier for me to cut every single component individually instead of trying to cut a very large holes in a very big beam of plywood which is very hard to cut foreign so I lay down every measurements and I take a knife to scribe every line that I need to cut to make sure that I have a clean cut close to the lines [Music] then on to the Press rail where I can start to drill some holes in the corners of all the openings I need to cut um and now it's just a matter of following the lines on this scroll saw and I have a pretty good surface finish on those cuts and it's going to be relatively precise although I do expect that once all the components are laminated I will have some corrections to do [Music] once every cuts are finished it's time to start gluing all the pieces together [Music] foreign first apply a good amount of glue and then I spread it out with the silicone roller [Music] I can now place all the components together and align them as well as I can at this moment and start to apply some clamps and I always check back and forth to make sure that all the components are aligned at the end that I'm pretty square with the table [Music] thank you [Music] [Music] I repeated the same process for all the legs and I let them set for a few days now I can remove the clamps [Music] [Music] foreign I now start to work on the braces that will link two legs together the gluing and clamping process is exactly the same as you saw before although this time I will have several cuts to do after the pieces are glued together [Music] foreign [Music] foreign [Music] for a second here on the table saw where I cut them to their final width I made sure to have some over material here to be able to cut them square and true once they're all assembled and laminated and I also need to cut them to their final length [Music] I quickly use the hand plane to make a little bit of a chamfer to help engage all the components together on assembly [Music] and of course here's a first test field that reveals that the components don't necessarily fit as expected together so I will need to remove some material you will see here I start by scribing the material I want to remove with a knife and I use a chisel to slowly remove a layer of plywood [Music] foreign [Music] [Music] that everything fits very well together this is a very satisfying part of the process and then I make sure everything is square so I guarantee that the components fit as I expect and I can now start to work on different other cuts and here it is on the braces I start by cutting those little square I need to remove in the corners on the miter saw and I finish all the cuts with the Japanese hand saw and here's a very satisfying moment where I can start to take all the components of the leg and assemble them together foreign so this is what you see me doing here [Music] and I will be checking the squareness of the frame to confirm that everything is great [Music] [Music] and now I can start to glue all the components together for a final assembly [Music] thank you [Music] foreign [Music] together and I can manipulate them comfortably I will start to pre-drill all the holes I need to install the casters at the bottom of the legs [Music] you can see here those two legs pretty much finished and I can start to work now on both the top and bottom cross frames that I have that link both legs together to form the frame [Music] [Music] foreign [Music] [Music] again here several cuts are needed to accommodate the joinery and the pegs that I will install on the top of the legs to hold the table top that's what you see me doing here and when all the cuts are made I can glue all the components together [Music] so as you see here I have the small cross braces of these top and bottom frames and here are all the parts of the top cross frame and as I mentioned the top of the work frame is going to be located and held in place using some pegs on the top of the Cross frame so here you see me cutting them and assembling them with glue [Music] foreign [Music] [Music] now that these pegs are glued together this brings me to the next step on the frame you can see a glimpse here of the frame pre-assembled and I now start to drill the holes I will need to install the long bolts and Barrel nuts to hold the frame together [Music] once all these holes are pre-drilled I disassemble the frame and on the end of every cross frame I need now to drill cross holes to accommodate the barrel nuts that I use for assembly now when this is done I install all the barrel nuts in place and I use a little bit of hot glue to hold them in place and I install a screw to make sure that while the glue sets that the baron nuts are in the right position [Music] and now I start to work on the table top you can see the first component here with the cuts that I need to do all laid out the stable top is made of a shell of 17 millimeters plywood which is going to be filled with MDF for all the cuts you see me do here I work the same way so I scribe the line with the knife and then when I come back with the router to finish the cut I'm sure that I'm not going to tear out any fibers then I remove some material with the Chisel to establish the edge I also have several holes I need to make all across the top surface so at this stage I take a small drill bit and I pre-drill all of them [Music] on what is going to be the router lift opening you see me use a Fastener bit to establish the corners of a cut I need to make with the router using a three-quarter inch Fastener bit I now start to drill all the dog holes I laid out all across the surface [Music] for the very large cuts that are all the way through I start by removing most of the material with the jigsaw [Music] now that most of the material have been removed I can install some fences and use the router to finish the cuts [Music] [Music] as I mentioned the workbenched up is going to be a shell of plywood so I will need to install strips on the side of this panel here that's why it's cut at 45 degrees I free cut everything with a circular saw but now I need to bring it to a sharp edge with a router that's what you see me doing here [Music] here I start to work on those side strips they have been cut to 45 degree lengthwise and here I also need to cut the tips at 45 degrees now that these strips are ready I can start to glue them on the workbench top and to do so I use a nail gun to hold everything in place [Music] foreign [Music] [Music] [Music] for the MDF material filler I pre-cut the first panel to fit inside the shell and I will lay it down there so I can go from underneath and pre-trace all the cuts I need to make on the MDF [Music] and I also transfer any mounting holes I need [Music] then I remove the panel from the shell and I pre-drilled the corners of every cut I need to make then I use the jigsaw to cut all around foreign [Music] [Music] for the second layer I didn't care if the MDF wasn't filled all the way so I just used some scraps I had around to fill the voids and I did not film the third layer because it's very similar to the first one now that the filler material is ready I can install it in the plywood shell and I do so by applying glue first and then I lay down a panel and fix it in place with the nail gun and I just do the same thing for every layer foreign [Music] [Music] [Music] benched up almost finished and ready to be assembled [Music] and here's another very satisfying moment where I need to reassemble the frame together to install the top on it and finish some operations all right [Music] foreign [Music] [Music] [Music] foreign I can now install the top on the frame and I can transfer the six mounting holes in the pegs underneath them and then I will have to remove the top again to finalize these holes [Music] [Music] and just like I did for the cross frame I installed the barrel nuts in the backs and set them in place with some hot glue [Music] foreign and I can place it up in its location again and finally fix it with the mounting screws and this completes the First Assembly of the workbench frame this is it for this video but there will be more to come in this workbench build Series so stay tuned for next and if you enjoyed this video please like And subscribe and thanks for watching

Channel: Mat's Workshop

Views: 282,689

Keywords: Small workshop, Woodworking Workbench, workbench, tablesaw workbench

Id: ogzirvWUIe4

Length: 26min 59sec (1619 seconds)

Published: Mon Mar 06 2023