Here’s a simple weekend project: My workshop needed a sturdy, flat work surface that I could access from all sides without a wall in my way, so I built the rock-solid workbench pictured here. This beefy bench is constructed from 2-by-6’s, 2-by-4’s and 2-by-2’s. I first ripped the rounded edges off the lumber, so each 2-by-4 measured 3 inches, and each 2-by-6 measured 5 inches. Then I assembled the bench according to the diagram shown below, sizing the height for a 6-foot tall person to work comfortably, but you can adjust the height of your bench accordingly.
I used 2-1/2-inch No. 8 wood screws when nailing through 2-by lumber into the face of another 2-by board. However, I used 3-inch screws when nailing through 2-by lumber and into the edge of a board.
You have the option of making the legs from 4-by-4 lumber and notching them as necessary. However, I made them from 2-by-4’s, spacing the blocks to accept the table top and lower shelf.
 
The bottom shelf is supported by 2-by-2’s attached to the inside of the lower box frame. Make the bottom shelf by cutting your sheet material of choice to fit flush into the lower frame, and fasten to the 2-by-2’s with 1-5/8-inch wood screws.
The sturdy top is nothing more than a solid-core door from Lowe’s, centered on the table frame and screwed to the 2-by-4 brackets from beneath. You can also construct the table from doubled sheets of plywood or even build a butcher-block top—you’ve got plenty of options to customize this table in any way that better suits your needs.
Side Note: A super nice addition to any workbench is the new IQ Vise™ from Work IQ Tools. We were able to demo this innovative new tool at the 2024 National Hardware Show. It features a ball and socket design that allows 360-degree rotation at any angle while supporting 130 ft/pounds of torque. Plus, it includes a compression lever in the front that gives the vise even more functionality by allowing it to lay down flat, lock at any angle or rotate for optimal work positioning. This vise makes for a terrific workbench partner that solves problems, eliminates workarounds and provides an extra set of hands. Check it out here: extremehowto.com/work-iq-tools-debuts-game-changing-new-workbench-tools
