Lightweight

Folding
Workbench
Build Plans

By Thomas Gojkovich

www.thomascustomwoodworks.com

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**VIDEO PLANS**
These plans also come with video plans which I highly recommend you use
to follow along with as you build the Lightweight Folding Workbench. The
instructional video is an unlisted YouTube video on my YouTube channel.
Although YouTube is where the video is located, this is not a typical
YouTube video. It is an extremely detailed instructional video that will walk
you through every step of the build including every cut, joinery method,
assembly, and installation.

The link for these video plans is below this paragraph. I ask that you do
not share this link with anyone and if your friends and family are interested,
I kindly request that you encourage them to purchase these plans. Thank
you!

Link for video plans: https://youtu.be/7k3vl1HP-v4

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Introduction
Introducing the Lightweight Folding Workbench Plans - the perfect solution for both
beginners and advanced builders seeking a space-saving workbench. These
meticulously crafted plans provide detailed written and video instructions, ensuring a
seamless construction process for all skill levels.

Key Features:

​ Mobile Design with Retractable Casters: Enjoy the flexibility of a mobile

workbench that effortlessly moves around your workspace. The retractable
casters provide stability during work and convenient mobility when needed.
​ Space-Saving Folding Mechanism: Designed for those with limited space, this
workbench easily folds away, allowing you to reclaim valuable floor space when
not in use. Ideal for small workshops, garages, or multifunctional spaces.
​ Lightweight Construction: I understand the importance of a portable
workbench. These plans emphasize lightweight materials without compromising
durability, making it easy to move and transport your workbench wherever your
projects take you.
​ Cost-Effective and Minimalist: Save both time and money with my
budget-friendly plans. The workbench is constructed using minimal materials
without sacrificing quality, making it an economical choice for craftspeople.
​ Versatility for All Skill Levels: Whether you're a beginner honing your skills or
an advanced builder looking for a practical addition to your workspace, these
plans cater to all skill levels. The detailed instructions ensure a smooth
construction process from start to finish.
​ Detailed Instructions: My plans come with comprehensive written and video
instructions, guiding you through each step of the construction process. Visual
learners and those who prefer written guidance will find our instructions
user-friendly and easy to follow.

Invest in the Lightweight Folding Workbench Plans today and elevate your craft.
Transform any space into a functional workshop without breaking the bank, and start
building with confidence.

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Approximate Cost
Plywood (3/4” 2’ X 4’ Shop Birch): $35
2X4 Construction Pine: $20
Retractable Casters: $30
Latches: $20
Hinges: $20
TOTAL: $125

Tools Needed
Basic Tools:
● Drill Bit Set https://amzn.to/3U7n2Fd
● 3/8 inch Forstner Bit https://amzn.to/3FNekrb
● Pocket Hole Jig & Drill Bit https://amzn.to/3U8z6pB
● Kreg Pocket Hole Jig Clamp https://amzn.to/3TiKPRm
● Hand Saw
● Measuring Tape
● Clamps (long and short)
Power Tools:
● Miter Saw (optional but convenient)
● Table Saw
● Power Drill

Materials Needed
● Toggle Clamp Latches (2) https://amzn.to/46ZHC0E
● Retractable Casters (4-pack): https://amzn.to/3GChw9f
● Hinges (10): https://amzn.to/47wagH3
● Titebond 1 or 2 Wood Glue https://amzn.to/3FLaWgz
● 3/8” dowels (optional)
● 1” Construction Screws (16)
● 2” Construction Screws (4)
● 2 1/2” Construction Screws (12)
● 2 1/2” Pocket Hole Screws (8)
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Lumber
Lumber Quantity U.S. Nominal U.S. Actual Metric Dimensions
Dimensions Dimensions
Plywood 1 3/4” x 2’ x 4’ 3/4” x 2’ x 4’ 18 mm x 60.96 cm x 1.22 m

Pine 6 2” x 4” x 8’ 1 1/2” x 3 1/2” x 38.1 mm x 88.9 mm x 2.44 m

8’

Hardwood 1 4/4” x 5” x 5.5’ 3/4” x 5” x 5.5’ 18 mm x 127 mm x 1.676 m

(optional)

Disclaimer:
When building a project using this plan you should not rely solely upon the information and
techniques discussed and displayed on this site. Rather, you should fully research each
technique and decide for yourself what is the safest possible work method for you.

All information contained in this plan should be independently verified and confirmed.

Thomas Gojkovich and Thomas Custom Woodworks do not accept any liability for any loss
or damage whatsoever caused in reliance upon information from these plans.

Reader/viewer agrees to indemnify and hold harmless Thomas Gojkovich and Thomas
Custom Woodworks from and against any personal injury, damages, costs and expenses,
including any legal fees, potentially resulting from the application of any of the information
provided by Thomas Gojkovich and Thomas Custom Woodworks. This disclaimer applies to
any damages or injury caused by any failure of performance of this build.

Reader agrees to assume all risks resulting from the application of any of the information
provided by Thomas Gojkovich and Thomas Custom Woodworks.

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Step 1:
Cut your 2’ X 4’ plywood Table Top into 2 pieces with a track saw, circular
saw, or on your table saw: 1 piece (the large table top piece) will be 18” X
48” and one piece (the small table top piece) will be 6” X 48”.

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Step 2: Hardwood Edge-Banding (Border)

Cut your 3/4” thick hardwood or pine edge-banding pieces to their final
dimensions and glue them to 3 sides of the Large Table Top Piece and 3
sides of the Small Table Top Piece. You do not need edge-banding on the
fourth side because that is where the 2 table top pieces will come together.

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Step 2 Continued:

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Step 3:
Cut 6 pieces to their final dimensions of 33 1/2” long for the Table Legs out
of construction lumber (2x4s). Then cut a half-lap joint that will be 3 1/2” X 3
1/2” (the width of your 2x4) near the top of all 4 of these pieces (1 inch from
the top edge) and a half-lap joint that is 3 1/2” X 3 1/2” and 7” from the
bottom of all 4 of these pieces. The other two 33 1/2” long pieces will be
used in a future step and do not cut the half laps in these other 2 pieces.

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Step 4:
Cut 4 pieces 21” long which will be the Lower Leg Support Pieces (2) and
the Upper Leg Support Pieces (2). Cut a half lap on both ends of each
Upper Leg Support Pieces and each Lower Leg Support Pieces. These will
be 3/4” deep (half the thickness of the wood) and 3 1/2” in from the edge.

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Step 5:
Cut a notch in the exact middle of each Lower Leg Support Piece with a
dado stack (or your regular blade with multiple passes) on your table saw
that is 1 1/2” wide and 1 3/4” deep (half the thickness of the 3 1/2” board).

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Step 6:
Attach the Lower Leg Support Pieces and the Upper Leg Support Pieces to
the legs using glue and 8 recessed 1” construction screws for each leg
structure. There will be 4 screws for each Lower Leg Support Piece and 4
screws for each Upper Leg Support Piece. Recess the screws about 1/4”
and then hide them with 3/8” dowels (optional). Each screw will be secured
3/4” in from each side and there will be 2 of these leg structures. See video
plans for more details on how to complete this step.

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Step 7:
Cut 2 pieces of construction lumber to 46 1/2 inches in length. Then attach
these 46 1/2” pieces to the 2 leg pieces that are 33 1/2” long from Step 3
using glue and 2 1/2” pocket hole screws. We will call this structure the Leg
Base. Make sure to measure the top and bottom horizontal pieces in
reference to the Small Table Top Piece as shown in the video plans. These
2 pieces could be slightly shorter or longer than 46 ½ inches.

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Step 8:
Cut the diagonal cross-brace to size and attach it to the back of the Leg
Base using glue and 2 1/2” construction screws (4 screws total). Make sure
you do not hit the pocket hole screws when you drill the 2 1/2” construction
screws into the diagonal cross-brace.

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Step 9:
Attach the leg structures (2) to the Leg Base using four hinges total (2
hinges for each leg structure) and the screws that the hinges come with.
Make sure that the top of the upper hinges do not protrude above the Leg
Base.

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Step 10:
Cut 2 pieces of construction lumber to the dimensions of 3 1/2” X 3 1/2” and
glue them to the upper, outside corners of both leg structures. You will
attach the table top latches to these blocks later in the build.

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Step 11:
Attach 6 hinges to the underside of the Small Table Top Piece ONLY using
the small screws that came with the hinges. Make sure to attach them in the
exact same places shown in the picture below so they do not interfere with
the folding legs. On both sides the hinges are 1 1/2”, 8 1/4”, and 15” away
from the edge. Before you complete this step if you do not want there to be
a gap between both table top pieces when you secure them to the
workbench in Step 13 you will need to recess the middle of the hinge into
both table top pieces with a router to get rid of this gap. If you do this you
will need to chamfer the underneath edge (and maybe even cut a full 45
degree bevel) of both pieces so the table top can fold properly.

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Step 12:
Attach the Small Table Top Piece to the Leg Base using wood glue and 8, 2
1/2” construction screws that are evenly spaced. There will be 2 screws on
each short side plus 4 screws in the back. Each screw will be 1 1/16” away
from the outer edge.

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Step 13:
Fold the legs inward, then flip the workbench structure upside down to line
up the Small Table Top Piece with the Large Table Top Piece. Use the hinge
screws to install the hinges. There will be a gap between the Small Table
Top Piece and the Large Table Top so there is room for the middle of the
hinge but are welcome to recess the middle of the hinge into both table top
pieces with a router to get rid of this gap. If you do this you will need to
chamfer the underneath edge (and maybe even cut a full 45 degree bevel)
of both pieces so the workbench can fold properly.

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Step 14:
Cut a piece of construction lumber to 46 ½ inches (but measure your
workbench to make sure this is accurate). Cut a notch out on both ends with
a handsaw or a jigsaw that is about 1 1/2” in from the end and about 1 3/4”
in from the side edge (half the width of the wood). Use the technique I show
in the video plans for the exact dimensions of these notches. This is the
Lower Support Stretcher.

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Step 15:
Set the Lower Support Stretcher in place and install the table top latches.
Use 1 1/2” or 2” screws to secure the part of the latch that goes on the side
of the table top. Then attach the 4 retractable casters so the bottom of the
black mounting piece is 1 7/8” above the bottom of the leg (or follow the
paper installation guide if your casters came with that). See video plans for
more details on how and where to attach the casters. Lastly, put finish on
the table top (optional). You are DONE!

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