Workbench with adjustable-height top

Do you work on engine blocks? How about fixing that old screen door? Maybe you’re a
model car builder or you like to tinker with building and rebuilding computers. This
rock-solid, adjustable-height workbench is for you.

The older I get, the more I feel aches and pains creeping up on me. After spending 35+
years bent over a woodworking bench; working in a number of commercial cabinetmaking
and furniture making shops, my back kept telling me to get smarter about how I was treat-
ing it. Also, my eyes were letting me know that I needed thicker and thicker lenses in my
glasses. I love woodworking and designing new projects, so I put those two passions to
work and came up with a workbench that would treat my back and eyes with the respect
they now deserve after serving me so well all these years.

Several criteria were involved in designing this bench: One, it had to be rock-solid. Two, it
needed to have a top that could be adjustable in height. When using a hand plane, I like a
lower bench height, and, when installing inlays on guitar necks, I like the bench height up
high so I can see what I’m doing. Three, it had to cost less that $200.00US. Four, I didn’t
want to spend a month or two of weekends building it. Five, it needed to be simple to
build; I have plenty of storage in my toolboxes and wall cabinets, so it didn’t need to have
shelves or drawers. Six, uh, I don’t remember, I guess that’s another thing about getting
older; my memory isn’t what it used to be.

Now, where was I? Oh yeah, the benchtop is height adjustable, from 35"- 45". The lower
35" height is possibly too high for some folks. Keeping all other parts the same dimensions
as per the cutting list, cutting the base leg parts J, K, L and N shorter will let you set the
height to your personal liking (see the 4-view drawing).

The bench can be constructed from two sheets of ¾" × 4' × 8' sheets of A/C construc-
tion-grade plywood, ten yellow-pine 2×8s eight feet long, a large bottle of glue, a box of #8
× 1½" flat-head sheet-metal or wood screws (plus a few other screws meantioned in the
following text), and a mechanical lift jack. For the lift legs you’ll need four strips of wood
¼" × 1¾" × 20½". I cut two strips of ¾" plywood to these dimensions, turned them on edge
and ripped them to the ¼" thickness.

Build the top

The benchtop can be adapted for your own personal needs in any manner you desire. For
example: drilling bench-dog holes, adding a vise(s); one on the end and another on the side,
attaching a tool tray, etc.
The 3"×25"×66" benchtop is made of construction-grade yellow pine, which is heavy and
strong; perfect for a benchtop. Untreated yellow-pine 2×4s are usually difficult to find, so
you’ll most likely need to buy 2×8s. Try to find wood with the straightest grain. The
yellow pine will have too much moisture to start using it right away, so let the wood
acclimate to your shop for a couple of weeks. (While the wood is acclimating, you can
start building the base and lift.)

Then rip the 2×8s to rough width and let them sit for another week or two. The wood
should now be stable enough to use. If not, let it sit another week or so.

Plane the boards to final thickness and glue them up into four groups of five boards each.
After the glue sets, plane each group to thickness (which is now the width of each plank).
Glue up the groups to make the full-size top. After the glue dries, use your jack plane to
level the bottom and top sides.

Base Assembly

Cut the parts for the base assembly as you need them, as per the base assembly drawing,
which shows the assembly steps in sequence. The plywood you use may not be exactly
¾" thick, so you’ll need to double check measurements as you build. Note: When
assembling the leg parts, use a ¾"×4×6" spacer when installing parts L and M. Then, use
a 2¼"×2¼"×23" spacer to ensure that the leg channels are square and are the proper
inside dimensions.

Cut the vertical slots in one each of part T and part U. As per the assembly drawing,
assemble the short U-shaped rails and attach these assemblies to the legs. Then attach the
four T parts. This completes the two end assemblies of the base.

Assemble the long U-shaped rails and attach them to the end assemblies. Starting at the
top of the long sides, install one part Q, then two N parts, then another Q part and finally,
two N parts. Do this on each long side. Attach the support rails W to the support plate X.
Install this support assembly on the lower two end rail assemblies. The base is now
complete. Note: The base is best assembled on a flat surface, making it easy to keep it
level and square.

The Lift

Cut one set of leg parts. Dry assemble one leg, using screws to hold the parts together.
Check the fit of the leg in the channel in the base assembly. If it fits just a little snug,
that’s okay. If it’s too loose, you’ll need to cut the leg parts a little wider and cut the ¼"-
thick strip of wood (leg part #2) a little thicker. When the leg is the correct dimensions,
cut the rest of the leg parts accordingly and glue up four legs. Just to be sure everything is
okay, check the fit of the legs again, and, if necessary, remove a little material from the
two inside sides of the legs using your table saw. The legs should slide smoothly up and
down in the channels of the base.

Cut out the rest of the lift assembly parts as you go. Note: When assembling the lift, drop
an 8"-long spacer into each leg channel in the base, then, place a leg in each channel. The
spacers will hold the legs up high enough for assembling the rest of the lift.

The Lift Jack

The 3"×25"×66" benchtop, made of yellow pine, plus the weight of the lift, weighs about
130-150 pounds, so a strong lift is essential for raising and lowering it.

The easiest lift mechanism to use is a mechanical scissors jack, which is commonly used
to level travel trailers. The important thing is to locate the jack in the center of the bench.

Have a friend or spouse help you lower the lift into the base leg channels. Now, set the
benchtop in place. Place the lift jack on the lower support beam WX and run the jack up
until it contacts the upper support beam YZ. Raise and lower the jack a few times,
moving it as necessary to fine tune the final location of the jack. Using #10×2" round-
head sheet-metal screws, attach the jack to the top of the lower support beam WX and to
the bottom of the of the upper support beam YZ.

Note: I cut the jack’s screw handle at the first bend from the end that attaches to the jack.
I welded an extension rod to this cutoff (see detail in 4-view drawing). Add enough
length so the extra rod protrudes through Part T at the end of the base assembly. A
battery-powered drill can be chucked to the extended rod to run the lift up and down. Or,
if you prefer, you can weld the rod extension in place and reattach the part you just cut
off to the end of the rod extension. Then you can hand crank the lift up and down.

Finishing Touches

The benchtop is attached to the lift using four, ¼"×2" lag bolts, inserted up through holes
drilled in the long spacers (D) of the lift. You can paint, stain and finish or leave the
bench as raw wood. Wax the legs of the lift so they will slide easily in the bench leg
channels. The benchtop is left unfinished.
 Cutting List

Qty Part Description Length Width Thickness Material

Top
20 A* Benchtop rails 66" 3" 11⁄4" yellow pine

Lift
2 B Long outer rails 441⁄2" 4" 3⁄4" plywood
2 C Long inner rails 38" 4" 3⁄4" plywood
2 D Long spacers 38" 13⁄4" 3⁄4" plywood
2 E Short outer rails 211⁄2" 4" 3⁄4" plywood
2 F Short inner rails 211⁄2" 4" 3⁄4" plywood
2 G Short spacers 181⁄2" 11⁄2" 3⁄4" plywood
2 Y Support rails 441⁄2" 5" 11⁄2" 2×6 spf
1 Z Support plate 441⁄2" 6" 3⁄4" plywood
4 H Legs (5 parts each) 201⁄2" 21⁄2" 21⁄2" plywood
8 #1 Leg parts 201⁄2" 13⁄4" 3⁄4" plywood
4 #2 Leg parts 201⁄2" 13⁄4" 1⁄4" plywood
4 #3 Leg parts 161⁄2" 21⁄2" 3⁄4" plywood
4 #4 Leg parts 161⁄2" 13⁄4" 3⁄4" plywood

Bench
4 J** Inner leg parts 23" 4" 3⁄4" plywood
4 K Inner leg spacers 23" 21⁄2" 3⁄4" plywood
4 L Outer leg spacers 63⁄4" 21⁄2" 3⁄4" plywood
4 M Outer leg spacers 81⁄4" 21⁄2" 3⁄4" plywood
4 N Outer leg blocks 63⁄4" 4" 3⁄4" plywood
4 P Outer leg blocks 81⁄4" 4" 3⁄4" plywood
4 Q Long outer rails 46" 4" 3⁄4" plywood
4 R Long inner rails 38" 4" 3⁄4" plywood
8 S Long spacers 38" 21⁄2" 3⁄4" plywood
4 T*** Short outer rails 231⁄2" 4" 3⁄4" plywood
4 U*** Short inner rails 17" 4" 3⁄4" plywood
8 V Short spacers 17" 21⁄2" 3⁄4" plywood
2 W Support rails 46" 4" 11⁄2" 2×6 spf
1 X Support plate 46" 3" 3⁄4" plywood
4 AA Feet 31⁄2" 31⁄2" 3⁄4" plywood

*Using 2×8×8' material yields 2 rails. 10 needed for 20 rails.

**Cut 2, 3⁄4"× 4" notches in one long edge of each part. See plans for detail.
***One each of parts T and U have a vertical slot for the jack’s wrench handle.
 A Benchtop rails (20)

F Short inner
rails (2)

H Leg (4)
D Long Y Support
spacers (2) rails (2)

C Long inner Z Support

rails (2) plate
G Short
X Support spacers (2)
plate

B Long
outer rails (2)

E Short outer
rails (2)
S Long
spacers (8 )
J Inner leg
R Long inner parts (4 )
rails (4 )
K Inner leg
spacers (4 )
AA feet (4 ) U Short inner
rails (4 )
T Short outer
Q Long outer P Outer leg W Support rails (4 )
rails (4 ) blocks (4 ) rails (2 )

M Outer leg
spacers (4 )

L Outer leg
spacers (4 )

N Outer leg V Short

blocks (4 ) spacers (8 )

Exploded View
 2 1⁄ 2"

Leg part, short ⁄

3 4"
3" 6" 1 1⁄ 2"
Leg part, short

Leg part, long ⁄

3 4"

Leg part, long ⁄

3 4"

Leg part, long ⁄

1 4"

44 1 ⁄ 2 "
3 4" ⁄ 1 3⁄ 4"

Full-Scale Leg Detail Top View T

Straight rod F 6" 1 1⁄ 2"
extends past Y
Part T.
23 1 ⁄ 2 " 25 "
Cut here.
G
Z
E Q C B D

Weld straight
Straight rod rod here.
extends past 46 "
Part T.
Top View

23 1 ⁄ 2 " 44 1 ⁄ 2 "

E 4" E
43 "
Y
Y B
6" H Z
Z ⁄
3 4" 1"
20 ⁄ 1 2"

39 1 ⁄ 2 "
18 1 ⁄ 2 "
2 1⁄ 2"
2 1⁄ 2"
Q
Q
4" 46 "

P J P W P
X
W ⁄
8 1 4"

23 3 ⁄ 4 "
23 ⁄1 2" 4"
N N
Q
T 38 "
⁄
2 1 2" 6 3⁄ 4"
4"
⁄
3 4"
3 1⁄ 2"
3" 4" AA
If the lower bench height
is too high for you, cut an
End View Side View inch or two from the bottoms
of the base parts J, K, L and N.
4-View Drawing
 Assembly Steps 31⁄2"
1. Glue leg parts J, K, L, & M Part U X Support
together to form 4, ⁄
3 4" AA foot plate
U-shaped legs.
2. Glue parts S (1) & R (2) Part T 3"
together to form U-shaped rails. W Support
3. Glue parts U (1) & V (2) rails (2)
together to form U-shaped rails.
4. Attach assemblies SR and UV One part T and one Part U 7
to the leg assemblies. have a 3⁄4"× 3" slot in their centers Q Long outer 6
5. Attach parts T to base for the jack handle extension. rails (4 )
assembly.
6. Starting at top of base, attach
one part Q, then two parts P,
R Long inner
then one part Q and finally, rails (4 )
2 parts N.
7. Assemble part X & parts W.
8. Install assembly WX to center
of lower end rail assemblies.

S Long
spacers (8 )
V Short
spacers (8 )

4 P Outer leg
blocks (4 )
AA feet (4 )
4 8

R Long inner 6
When assembling the legs rails (4 )
for the base, use a N Outer leg
21⁄4" × 21⁄4" × 24" T Short blocks (4 )
5
spacer block to help rails (4 )
K Inner leg maintain the proper
spacers (4 ) dimensions for ⁄
3 4"

the channels.
M Outer leg
spacers (4 ) U Inner base 4"
J Inner leg rails (4 )
parts (4 )
2 3
L Outer leg
Use a 3⁄4" × 4"× 6" spacers (4 ) 81⁄4"
spacer to align V Short Part J
parts L and M. spacers (8 ) detail

4"
M Outer leg
spacers (4 ) 1 46"

4" W Suppport Rail 63⁄4"

L Outer leg Base Assembly 1"
spacers (4 )
4" 4"
Assembly Steps C Long inner
rails (2)
1. Glue leg parts together to
make 4 legs. B Long outer Y Suppport
2. Install parts F, then parts C rails (2) 6
F Short inner rails (2)
3. Attach parts W to part X rails (2)
D Long
4. Attach YZ assembly in center spacers (2)
of lift.
5. Install parts D & G
6. Install parts B, then parts E

2 5
6
H Legs (4)

5 Z Suppport
plate
13⁄4"
13⁄4" 4 G Short
#2 leg spacers (2)
parts (4 )
21⁄4"

#3 leg
parts (4 ) E Short outer
#1 leg rails (2)
parts (8 )

#4 leg
parts (4 )
#3 leg 31⁄4"
parts (4 )

4" 5" Y Suppport Rail

Lift Assembly
441⁄2"
1
Assembly Steps
1. After machining the rails to rough
(slightly oversized) size, glue up 4 sets
of 5 rails each. Machine these 4 assemblies
to thickness and width.
2. Glue up the 4 sets to create
the top.

A Benchtop rails (20)

2

Top Assembly