MODERN

POWER TOOL
BENCH

© 2013 August Home Publishing Co.


modern
Power Tool Bench
With a large worksurface and plenty of storage,
this bench is sure to be the center of attention.
I’ve yet to see a shop that has enough worksurfaces.
Power tool storage is always at a premium, as well.
This workbench addresses both of these needs and
even throws in a convenient charging center for
cordless tools. It’s the perfect addition to any shop.
Let’s start with the large worksurface. It’s big
enough to handle a project of just about any size.
Look down below and you’ll find plenty of stor-
age for your power tools. Three removable totes are
ideal for storing tools like saws, drills, and sanders.
A deep cubby off to the side offers storage space
with a shelf to hold all your accessories.
1 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.
dream shop project
For all your battery chargers, a special shelf and
power strip on the end of the bench keeps them all
in one easy-to-reach spot. Built-in cord manage-
ment keeps the chargers neat and tidy.
As I’m sure you’ve already noticed, this bench
features some unique construction materials. Light-
weight aluminum legs and end rails create a mod-
ern look without sacrificing stability and strength.
This is one bench that will stand up to a lot of use.
The woodworking is pretty straightforward, and
the metal work is nothing you can’t handle. It’s a
combination that results in a rock-solid workbench.
Exploded View Details
OVERALL DIMENSIONS: 36"D x 72"W x 36"H

THICK HARDWOOD TOP

PROVIDES PLENTY OF
WORKSPACE
NOTE: CABINET MADE
FROM BIRCH PLYWOOD AND
POPLAR, THEN PAINTED

ADJUSTABLE
SHELF INCREASES
TOP IS SECURED WITH STORAGE CAPACITY
SCREWS THROUGH A PAIR
OF MOUNTING CLEATS

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 HARDWOOD
POWER STRIP KEEPS BATTERY- TUBING MAKES FOR TOTES FEATURE
POWERED TOOLS CHARGED STRONG YET LIGHT LEGS BOX JOINTS FOR
AND READY TO GO STRENGTH

NOTE: ALL ALUMINUM NOTE: RACK REMOVABLE TOTES

AND TOTES MADE PROVIDE STORAGE FOR
PARTS ARE 1⁄8" THICK FROM HARDWOOD POWER TOOLS

Materials & Hardware

A Legs (4) 3 x 3 - 34 Square Alum. Tube N Shelf (1) 183⁄4 x 281⁄4 - 3⁄4 Ply. AA Braces (2) 3⁄
4 x2-4
B Rails (4) 11⁄2 x 11⁄2 - 29 Alum. Angle O Shelf Edging (1) 3⁄ x 3⁄ - 183⁄
4 4 4 BB Cord Rail (1) 3⁄
4 x 2 - 25
C Sides (2) 17 x 291⁄2 - 3⁄4 Ply. P Stop (1) 3⁄ x 13⁄ - 381⁄
4 4 2
D Cleats (4) 3⁄ x 1 - 29 Q Guides (6) 3⁄ x 3⁄ - 28 Alum. Angle • (16) 12-14 x 3⁄4" Self-Drilling Screws
4 4 4
E Foot Pads (4) 3⁄ x 3 - 3 R Tote Sides (6) 1⁄ x 81⁄ - 28 • (20) #8 x 1" Rh Woodscrews
4 2 2
F Back (1) 20 x 60 - 3⁄4 Ply. S Tote Ends (6) 1⁄ x 81⁄ - 12
2 2 • (12) #8 x 1" Fh Woodscrews
G Bottom (1) 30 x 591⁄4 - 3⁄4 Ply. T Tote Bottoms (3) 111⁄2 x 271⁄2 - 3⁄4 Ply. • (30) #6 x 1⁄2" Fh Woodscrews
H Lower Rail (1) 61⁄2 x 60 - 3⁄4 Ply. U Tote Cleats (6) 3⁄ x 1 - 11
4 • (10) #8 x 11⁄2" Fh Woodscrews
I Inner Side (1) 29 x 11 - 3⁄4 Ply. V 1 1
Handle Bases (6) 1 ⁄2 x 1 ⁄2 - 5 Alum. Angle • (14) #8 x 11⁄4" Fh Woodscrews
J Divider (1) 29 x 131⁄4 - 3⁄4 Ply. W Handle Caps (6) 3⁄ x 1 - 5
4 • (1) Power Strip
K Stiles (3) 3⁄ x 11⁄ - 131⁄ X Top (1) 11⁄2 x 36 - 72 • (2) #8 x 3⁄4" Rh Woodscrews
4 2 2
L Upper Rail (1) 3⁄ x 2 - 60 Y Rack Shelf (1) 3⁄ x 8 -25 • (6) 1⁄4"-dia. Shelf Pins
4 4
M Mounting Cleats (2) 3⁄ x 2 - 591⁄ Z Rack Back (1) 3⁄ x 7 -25
4 4 4

2 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.
 NOTE: RAILS ARE
1
FIGURE
MOUNTED FLUSH TO
TOP OF LEGS
a.
RAIL SIDE VIEW FRONT VIEW
(1!/2" x 1!/2" - 29" Alum.) CLEAT
B LEG RAIL
(3" x 3" - 34" Alum.)
A CLEAT
12-14 x #/4" SELF-
TAPPING HEX-HEAD
SCREW
A 12

!/4 !/4

D SIDE
1 #/4

C SIDE
CLEAT
SIDE NOTE: RAILS
(17" x 29!/2" - #/4" Ply.) LEG
AND LEGS ARE
!/8"-THICK CLEAT
ALUMINUM
TUBING RAIL

RAIL

b. 2 !/8
!/4
D
CLEAT
(#/4" x 1" - 29") E LEG SIDE
#8 x 1" Rh
WOODSCREW CLEAT
!/4

building a solid RAIL TOP VIEW

Bench c. SIDE VIEW !/8

FOOT PAD !/2

One of the unique features of
the workbench is the aluminum
frame assembly at each end. A
pair of 3" x 3" square aluminum
tubes are joined with two rails
made from aluminum angle.
These two frames form the foun-
dation for the rest of the bench.
Metal Work. You’ll start by
cutting the aluminum legs to
length. You can cut aluminum
with your miter saw or table saw,
RAIL but you’ll want to use the right
SELF-TAPPING SCREWS
CLEAT
LEG
SIDE
E FOOT PAD
(#/4" x 3" - 3")
saw blade. Use one designed spe-
cifically for cutting non-ferrous
metals or one with a triple-chip
grind and a negative hook angle.
A slow, easy cut is best.
The same cutting technique
applies to the angle rails. Once
they’re cut to length, you can set
them aside for now.
The hardwood foot pads start
out as square blanks. They’re
rabbeted on all four sides to fit
snugly inside the legs, as you can
see in Figure 1c. I used a few dabs
of silicone adhesive to attach
them to the bottom of the legs.
Bench Sides. The plywood
sides of the bench need a little
work after they’re cut to size.
Start by cutting a groove that
will be used for securing the bot-
tom panel (Figure 1). Next, cut
rabbets to form tongues on the
front and back edges (Figure 1b).
NOTE: ATTACH PAD WITH
SILICONE ADHESIVE
These tongues join with dadoes
in the cabinet back and front.
The last thing to do on the
sides is cut a pair of wide rabbets
(Figure 1b). These wrap around
the inside corners of the legs.
The sides are fastened to the
aluminum rails with cleats, as
shown in Figure 1. After gluing
the cleats to the sides, you can fas-
ten the sides to the rails through
predrilled holes, as illustrated in
Figure 1a and the photo at left.
Then you can fasten the side
assembly to the legs. I clamped
the rails in place and drilled
starter holes for the screws before
driving them in.
Cabinet Shell. The next order
of business is the cabinet that
connects the two leg assemblies.
Figure 2 shows how a bottom,
back, and lower front rail tie the
leg assemblies together. I started

3 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.
 2
FIGURE
with the large back panel. A
dado near each end fits over F
the tongue on the cabinet sides. BACK
(20" x 60" - #/4" Ply.) SIDE
A long groove aligns with the
grooves in the sides.
The bottom panel comes next.
As you can see in Figure 2, you’ll
need to cut a dado to accommo- G
date a divider. I drilled a series of BOTTOM
(30" x 59!/4" - #/4" Ply.)
countersunk holes from the bot- SIDE
tom centered on the dado to fas-
ten the divider later.
To trap the bottom panel in
place, I added a lower front rail.
Like the back, the ends of the
H
rail need dadoes. Then form a LOWER RAIL
rabbet along the top edge to fit SIDE a. (6!/2" x 60" - #/4" Ply.)
over the bottom. !/4
VIEW
To glue up the bottom, back, BOTTOM
and lower rail between the leg
assemblies, you’ll need some
BACK !/4 b.
LOWER
long clamps to secure the bot- RAIL
5#/4
c.
!/4
tom to the sides. The tongue SIDE
CLEAT BACK
and dado joinery helps keep
SIDE !/4
everything aligned when RAIL 19#/4
applying clamps. !/4
BOTTOM
Cubby. A divider and inner LOWER
RAIL #/4
side panel form a cubby for an
FRONT
adjustable shelf (Figure 3). Cut Figure 3 are identical in size. A BACK VIEW
them to size and drill holes for half lap is formed on the top end.
shelf pins before installing them. A groove in the two end stiles fit
Face Frame. To dress up the over the tongue on the side pan- create the half laps to mate with
front of the cabinet, I added a face els, as in Figure 3c. each of the stiles.
frame. The three stiles shown in Cut the top rail to size and Cleats. I made two long cleats
INNER SIDE to fasten the benchtop. Simply
3
FIGURE (29" x 11" - #/4" Ply.) predrill the screw holes before
I cutting dadoes to fit over the
divider. The cleats can then be
glued in place.
J
DIVIDER
(29" x 13!/4" - #/4" Ply.)
a. FRONT VIEW
#/4 19%/8

MOUNTING
NOTE: HOLES K CLEAT
M FOR SHELF PINS
MOUNTING ARE !/4"-DIA.
CLEAT !/4 DIVIDER
(#/4" x 2" - 59!/4")

L
UPPER RAIL
(#/4" x 2" - 60")
b.
K STILE
(#/4" x 1!/2" - 13!/2") SIDE VIEW CL
CLEAT
1

c.
BOTTOM
3!/4 2
!/4 TOP #/8 UPPER 20
#/8 !/4 VIEW RAIL STILE

4 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.
 adding the final
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 adjust-
able shelf is ideal for accessories.
The thick hardwood top makes
for a lot of working space. Finally,
the charging station keeps char-
gers and batteries organized and
easy to access whenever needed.
Paint. Before getting started { Convenient Storage. Sturdy totes hold a lot of tools and
though, remove the leg and rail accessories, and can be removed and carried anywhere.
assemblies to paint the cabinet. I
primed it first and then sprayed box-jointed sides results in a and aligned with the notch of
on a couple coats of paint. sturdy combination. Figure 5 the box joint on their respective
Shelf. There’s not a lot to do provides all the details. pieces, as you can see in Figures
when it comes to the adjustable Making the sides, front, and 5a and 5d on the next page.
shelf. It’s cut to size, and edging back of the totes is pretty straight- These offset grooves mean that
is applied to the front, as you can forward. They’re cut to length you need to form matching offset
see in Figure 4. but left a little wide. After cutting tongues on the tote bottom. Fig-
Guides. After re-attaching the the box joints, trim them to final ures 5b and 5d show you what
leg assemblies, install the drawer width to create full pins. I mean. A 1⁄4" tongue along the
stop and guides (Figure 4). Spac- Before moving on, there’s sides of the bottom mates with
ers help keep them square and something a little unique about the grooves in the tote sides. Like-
parallel as you fasten them. the tote bottom I need to men- wise, a 1⁄2" tongue on the ends of
Strong & Sturdy Totes. The tion. I wanted to hide the grooves the bottom engages the grooves
trio of totes is designed from for the bottom so they wouldn’t on the front and back of the tote.
the ground up to hold a lot of show up in the assembled box Pairs of Handles. After assem-
tools (photo above). The 3⁄4" ply- joint. The grooves in adjacent bling the tote, you can add a cleat
wood bottom combined with pieces are offset from each other and two-part handle at each end,
as in Figure 5c. The handle is
4
FIGURE
made from aluminum angle with
a hardwood cap. You can find out
NOTE: more details about how to make
DISASSEMBLE
LEG AND RAIL the handles by turning to Shop
ASSEMBLY TO
PAINT CABINET STOP Short Cuts on page 7.
(#/4" x 1#/4" - 38!/2")
P

SHELF
(18#/4" x 28!/4" - #/4" Ply.)
N

a. FRONT
!/8
VIEW b. EDGING

O
12 SHELF EDGING
(#/4" x #/4" - 18#/4")
#/4 !/4
SHELF
#6 x !/2" Fh GUIDE
Q PIN SIDE
WOODSCREW GUIDE VIEW
(#/4" x #/4" - 28" Alum.)

5 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.
 a. TOTE SIDE TOTE END

5
FIGURE
NOTE:
GROOVES
FOR TOTE
BOTTOM
SHOULD
!&/32 ALIGN
WITH
!/2 EDGE OF
NOTCH IN
!/4 BOX
JOINT
b. !/2

!/4

TOTE !/4
BOTTOM TOTE BOTTOM
(11!/2" x 27!/2" - #/4" Ply.)
!/4 S HANDLE CAP
T
R (#/4" x 1" - 5")
TOTE W
GUIDE SIDE

R NOTE: SEE
SHOP
c. SIDE VIEW TOTE CLEAT U
(#/4" x 1" - 11")
TOTE SIDE
(!/2" x 8!/2" - 28")
SHORT CUTS
ON PAGE 7
U FOR MORE
TOTE ON MAKING

d.
CLEAT TOTE HANDLE

HANDLE
BASE
#8 x 1" Fh
TOTE
WOODSCREW END
Hardwood Top. The next item
on the to-do list is gluing up 11⁄2"-
thick stock for the top (Figure 6).
After trimming it to final size,
install it with screws through the
pair of mounting cleats.
Charger Rack. The last thing
to do is build a rack that incorpo-
rates a shelf, power strip, and a
END V
TOTE
S HANDLE
BOTTOM !/2 (1!/2" x 1!/2" - 5" Alum.)
TOTE END
(!/2" x 8!/2" - 12")
SIDE !/4
VIEW the rail for wrapping the cords.
Now, assemble the rack and
cord rail to keep the cords neatly attach the power strip. For your
organized. You can see in Figure convenience, you can mount the
6 how it goes together. rack on either end of the bench.
After cutting all the parts to Finishing. I wiped on a few
size, I drilled the holes in the coats of varnish for the totes,
shelf for the charger power cords. rack, and benchtop. Then you’re
4
I also drilled the series of holes in ready to load the bench 2 with 1" DIA.
the cord rail then cut the slots in tools and get to work.
1!/2 1!/2

6
FIGURE
#/8
NOTE: TOP OVERHANGS CL
FRONT OF BENCH #/8
BY 3" AND
X IS CENTERED SIDE TO SIDE
9 TOP
a. FRONT MOUNTING
CLEAT
TOP
(1!/2" x 36" - 72") RACK SHELF VIEW
VIEW
TOP

LEG RACK SHELF

(#/4" x 8" - 25") 2
4
1" DIA. c.
#8 x 1!/2" Fh
WOODSCREW Y
1!/2 1!/2

#/8
NOTE: USE CL
AA AA #/8
#8 x 1!/4" Fh
WOODSCREWS BRACE BRACE
(#/4" x 2" - 4") 9 TOP
RACK SHELF
RACK SHELF VIEW

45°
2!/2
2&/8 CORD RAIL
CL d.
POWER
2 STRIP
BB 1
SIDE CORD RAIL
VIEW RACK
BACK (#/4" x 2" - 25")
#/8
Z !/4
RACK BACK 2 1" DIA.
b. POWER
STRIP (#/4" x 7" - 25") 2&/8 TOP VIEW

6 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.
 Shop
Short
Cuts
The tote handles for the work-
bench are made from a section
of aluminum angle with a hard-
wood 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
1⁄ "-kerf saw blade to cut a slot
8
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 cor-
ners of one leg with a file, as you
can see in Figure 4. At the drill
press, I drilled a pair of counter-
sunk screw holes to fasten the
handle assembly to the tote.
The cap is fastened to the other
leg of the angle. To do this, I
slipped it onto the angle and then
drilled a couple of countersunk
pilot holes on the underside of
the cap. Take care not to drill all
the way through. Then fasten the
handle to the end of the tote.

1 NOTE: BLANK SIZE

IS #/4" x 4" - 5" (6
2
BLANKS REQUIRED)
BACKER
BOARD
a. CL
a. TABLE SAW
END FENCE
VIEW END
HANDLE VIEW
BLANK %/8
!/4" ROUNDOVER HANDLE
BIT BLANK NOTE: !/8" KERF
IS CENTERED
ON BLANK

3 4
FIGURE

1!/2" x 5"
ALUMINUM
ANGLE
ROUTER HANDLE 1
TABLE FENCE CAP
PUSH
BLOCK
!/2"
RAD.

a. PUSH
BLOCK a. END VIEW
COUNTERSINK
!/4" ROUNDOVER FOR #8
BIT WOODSCREW

#6 x !/2" Fh
END VIEW WOODSCREW

7 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.
 Power Tool Bench
Materials List
A Legs (4) 3 x 3 - 34 Square Alum. Tube N Shelf (1) 183⁄4 x 281⁄4 - 3⁄4 Ply. AA Braces (2) 3⁄ x 2 - 4
4
B Rails (4) 11⁄2 x 11⁄2 - 29 Alum. Angle O Shelf Edging (1) 3⁄ x 3⁄ - 183⁄
4 4 4 BB Cord Rail (1) 3⁄ x 2 - 25
4
C Sides (2) 17 x 291⁄4 - 3⁄4 Ply. P Stop (1) 3⁄ x 13⁄ - 381⁄
4 4 2
D Cleats (4) 3⁄ x 1 - 29 Q Guides (6) 3⁄ x 3⁄ - 28 Alum. Angle • (16) 12-14 x 3⁄4" Self-Drilling Screws
4 4 4
E Foot Pads (4) 3⁄ x 3 - 3 R Tote Sides (6) 1⁄ x 81⁄ - 28 • (20) #8 x 1" Rh Woodscrews
4 2 2
F Back (1) 20 x 60 - 3⁄4 Ply. S Tote Ends (6) 1⁄ x 81⁄ - 12
2 2 • (12) #8 x 1" Fh Woodscrews
G Bottom (1) 30 x 591⁄4 - 3⁄4 Ply. T Tote Bottoms (3) 111⁄2 x 271⁄2 - 3⁄4 Ply. • (30) #6 x 1⁄2" Fh Woodscrews
H Lower Rail (1) 61⁄2 x 60 - 3⁄4 Ply. U Tote Cleats (6) 3⁄ x 1 - 11
4 • (10) #8 x 11⁄2" Fh Woodscrews
I Inner Side (1) 29 x 11 - 3⁄4 Ply. V Handle Bases (6) 11⁄2 x 11⁄2 - 5 Alum. Angle • (14) #8 x 11⁄4" Fh Woodscrews
J Divider (1) 29 x 131⁄4 - 3⁄4 Ply. W Handle Caps (6) 3⁄ x 1 - 5
4 • (1) Power Strip
K Stiles (3) 3⁄ x 11⁄ - 131⁄ X Top (1) 1 ⁄2 x 36 - 72 • (2) #8 x 3⁄4" Rh Woodscrews
1
4 2 2
L Upper Rail (1) 3⁄ x 2 - 60 Y Rack Shelf (1) 3⁄ x 8 - 25 • (6) 1⁄4"-dia. Shelf Pins
4 4
M Mounting Cleats (2) 3⁄ x 2 - 591⁄ Z Rack Back (1) 3⁄ x 7 - 25
4 4 4

Cutting Diagram
#/4" x 8!/2" - 96" POPLAR (5.7 Bd. Ft.)
L D
M D
M K
K
P

#/4" x 8!/2" - 96" ASH (5.7 Bd. Ft.) O

U BB E E
U Z
Y W W E E
U
AA AA

!/2" x 9" - 96" ASH (THREE BOARDS @ 6 Sq. Ft. EACH)

R R S S

1!/2" x 7!/2" - 72" ASH (FIVE BOARDS @ 7.5 Bd. Ft. EACH)

8 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.
 !/2" x 9" - 96"

Cutting Diagram cont.

1!/2" x 7!/2" - 7

48" x 96" - #/4" PLYWOOD

F N

C C

48" x 96" - #/4" PLYWOOD

G J I

T T T

9 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.
 MAIL Project Sources
ORDER
SOURCES As far as hardware goes for the mod-
ern power tool bench, you’ll need 3"
Woodsmith Store
800-444-7527 square aluminum tube (88875K73),
12-14 x 3⁄4" screws (90064A580), 3⁄4"
McMaster-Carr aluminum angle (88805K44), and 11⁄2"
630-833-0300 aluminum angle (8982K134). All of
mcmaster.com
these can be found at McMaster-Carr.
The cabinet of the bench was paint-
ed with Benjamin-Moore Aura satin
paint, Fair Isle Blue color. The bench-
top, totes, and shelf were finished
with a wipe-on oil finish.

10 WoodsmithPlans.com SN13128 ©2013 August Home Publishing Co. All Rights Reserved.