Q–I have never liked working with sawhorses. I’m looking for a simple work platform or bench that I can use for various purposes around the house. My guess is that you were also frustrated with sawhorses. What do you use on your jobs? Is it easy to find one in a store? If not, how do you build one?
A–Sawhorses are OK for certain tasks, but I only use them as a last resort. My weapon of choice around the job site is a wonderful multipurpose carpenter’s bench that I make from scrap lumber. The environmentally friendly benches are usually made by lunch of the first day on the job.
I use the scrap lumber that is generated during the construction of the wooden subfloor or wall assemblies. The benches are far stronger than traditional sawhorses and they also serve as a tool caddy, emergency stepladder and a great place to sit and eat lunch.
To start this project you are going to need a circular saw, a drill with a 1/2-inch spade bit, a jig saw, a level, a framing square, a tape measure, a pencil, a screwdriver and some 2 1/2-inch-long, galvanized, coarse-threaded screws.
If you want a fancy bench you will need a router as well. The lumber requirements are simple. All you need is a 4-foot length of 2-by-12 and a 4-foot-by-3-foot piece of scrap 3/4-inch plywood or oriented strand board (OSB).
The completed bench measures 14 3/4 inches wide at the top, 32 inches long and 24 inches high. I always like to cut all of my lumber before I start to assemble the bench.
The legs of the bench are made from two pieces of 2-by-12 that measure 11 1/4 inches wide and 23 1/4 inches long. A V-notch is cut in the bottom of each leg so that just a 2-inch-long portion of the 2-by-12 contacts the ground at each corner.
All of the other bench parts are made with the plywood or OSB. Six pieces need to be cut in order to begin assembly. If you are using plywood, be sure that all pieces are laid out so that the longest dimension is parallel with the grain of the wood.
OSB layout is not as critical. The top measures 14 3/4 inches wide by 32 inches long. Cut out the top and bottom stabilizer braces next. The braces measure 3 inches wide by 30 inches long. The last piece to be cut is the bench’s bottom shelf. It measures 11 1/4 inches wide by 27 inches long.
The bench assembly begins by attaching the top braces to the top outside 1 1/2-inch-wide corner of the 2-by-12s. Once attached, the top of each brace should be flush with the top of each leg. Use two screws at each connection point.
The bottom braces are attached in the same manner. However, the bottom of the lower braces should be held up 4 inches from the bottom of the legs. The shelf can now be installed. If you cut your lumber correctly, it will fit snugly in between the legs and the bottom braces.
The underside of the shelf should be flush with the bottom edge of the lower braces. Install three screws through each brace to secure the shelf. The braces act as shelf sides and form a convenient storage area within the bench. You will find this to be a perfect place to store nails, shims, paint brushes or other items for different tasks.
The final piece to be attached is the top. Once again, if all cuts are accurate you will find that the top overhangs the legs and top braces 1 inch on all sides. Attach the top by driving at least three screws into each leg and two screws into each top brace.
Use the drill and jig saw to cut out a 2-by-4-inch rectangle in the center of the top. This cutout acts as a handhold to let you easily lift and transport the bench using one hand. Equip the router with a profiled bit to give the top’s outside edge and the interior edge of the handhold a finished touch.
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Have questions about the remodeling process? Write to Tim Carter, c/o The Chicago Tribune, P.O. Box 36352, Cincinnati, Ohio 45236-0352. Questions will be answered only in the column.
For illustrations, photos, and detailed plans for building Tim’s bench, send $2 and your name and address to Tim Carter at the above address. Ask for Builder Bulletin No. 227.
