Plywood workbench

The measurements

The top is two layers of 60 × 24. The base under it is 54 wide and 22 deep, so the top overhangs 3 at each end for clamping and 1 front and back. The sides are 34 9/16 tall: 36 less the two 23/32 layers.

The parts are typed, so you work the spans out yourself; the cut list has the results. For a cabinet worked out from the space, see the single cabinet.

The decisions

• Stock. 3/4" birch plywood for the top and base, 1/4" for the back, full 96 × 48 sheets.
• Bottom in 3/8" dadoes, 4" off the floor: room for your toes and clear of a wet floor.
• Shelf in 3/8" dadoes, midway between the bottom and the stretchers.
• Two 4" stretchers lie flat in 3/8" dadoes, flush with the tops of the sides. The top screws down through them.
• The back sits in a 3/8" rabbet along each side. Glued in, it keeps the base square.
• Grain. The sides are grain-locked; the rest may turn on the sheet.
• Layout. Max yield, 1/8" kerf.

The cut list

Grouped by size and material. The install notes are the notes on each part.

Install notes

1. Workbench, left side. 3/8" deep dadoes for the bottom, its underside 4" from the bottom, for the shelf, its underside at 18 15/16", and for the two stretchers, flush with the top; a rabbet 7/32" wide and 3/8" deep along the back edge for the back.
2. Workbench, right side. 3/8" deep dadoes for the bottom, its underside 4" from the bottom, for the shelf, its underside at 18 15/16", and for the two stretchers, flush with the top; a rabbet 7/32" wide and 3/8" deep along the back edge for the back.
3. Workbench, bottom. Sits in 3/8" dadoes in both sides, its underside 4" up from the floor; its back edge stops at the rabbet.
4. Workbench, shelf. Sits in 3/8" dadoes in both sides, its underside 18 15/16" from the bottom of the side; its back edge stops at the rabbet.
5. Workbench, front stretcher. Lies flat in 3/8" dadoes in both sides, flush with their tops and with the front of the base.
6. Workbench, back stretcher. Lies flat in 3/8" dadoes in both sides, flush with their tops and with the back of the base, in front of the back.
7. Workbench, back. Sits in a rabbet 7/32" wide and 3/8" deep along the back edge of each side, the full 34 9/16" height. Glue and nail it: it keeps the base square.
8. Workbench, top layer 1. Glue the two layers face to face, then screw the top down through the stretchers, 3" past the base at each end and 1" at the front and back.
9. Workbench, top layer 2. Glue the two layers face to face, then screw the top down through the stretchers, 3" past the base at each end and 1" at the front and back.

The sheets

Every part where the planner put it, with the kerf left open. The grain arrow marks the sides.

Build order

1. Break down the plywood from the sheet layouts and mark each part off in Cut mode.
2. Lay the sides down as a mirrored pair and mark the dadoes from the install notes.
3. Cut the dadoes for the bottom, shelf and stretchers, then the rabbet for the back.
4. Glue the bottom, shelf and stretchers into the sides. Square the base by its diagonals, then glue and nail the back.
5. Glue the two top layers face to face and screw them together from below.
6. Set the top on the base, 3" past each end and 1" past the front, and screw up through the stretchers.
7. Ease the edges and finish the top with a hard-wearing oil or poly.

Make it yours

Open the bench, change a size and optimize again.

• Make a cut list from your measurements
• Choose a layout strategy
• Mark parts off as you cut
• More cut list templates

Open this example