Building a Workbench on Wheels: Part Three

Building a workbench on wheels is a fairly simple project, having made quite a few allows me to share some of the finer points in building one that will last even under some pretty heavy loads. Building a rolling workbench 48 inches square will allow you to build one workbench using only one sheet of OSB.

The legs can be made by either nailing 2x4s together to double them or by using 4x4s. Personally I prefer 2x4s, because they are easier to work with and cut, and in my opinion, stronger than a single 4x4 post.

Wheels can be purchased from any hardware store. This is one area you don't want to scrimp on as cheap wheels now will only lead to headaches later. They are rated for weight, so decide now what you may try to carry on the rolling workbench later. The larger the wheel the more weight it will carry so invest in at least three inch wheels.

Be sure to get wheels with bearings in them and at least two that swivel, otherwise you will be unable to turn it while rolling. The wheels with a flat plate to attach the legs to are what you are looking for.

Be sure you add the height of the wheels into the calculation for total height when you are deciding how tall to make your workbench. Also add the thickness of the OSB on top.

Materials needed for building a rolling workbench:
You will need eight 45 inch 2x4s to attach to the legs for support, and for cross support of the top, and for cross support of the lower shelf. (Four eight foot 2x4s)
Four 2x4s 48 inches long also for supports. (Two ten foot 2x4s)
Eight 2x4s to make your legs with, at a length according to your needs (Probably four more eight foot 2x4s)
One sheet of 7/16 inch OSB
Two non swiveling wheels
Two swiveling wheels
Four 3/8 inch x 5 ½ inch hex head bolts
Eight 3/8 inch flat washers
Four 3/8 inch lock washers
Four 3/8 inch nuts (regular or nylox)
Box of #10 x 3 inch deck screws
Box of # 8 x 1 ½ inch deck screws
Box of 16d common nails

Tools needed for building a rolling workbench:
Circular saw
Drill with proper chuck for the type of screws you are using
Wrenches and sockets to tighten bolts
Framing hammer (claw)
Marking pencil
Speed square
3/8 inch drill bit
Chalk line or sheetrock square
Two eighteen inch bar clamps

Cut the eight 2x4s to the length you need for your legs, and clamp two of them together. Nail at angles in pairs every six inches, alternate angle of nail direction per pair. Avoid nailing the top four inches and the bottom seven inches of each leg set to keep from having interference with the bolts and screws. Repeat until all four legs are assembled.

Lay two legs on the floor with the tops in the same direction (nails missing last four inches) and place a 45 inch 2x4 across right at the top and flush with the outside edge of both legs. Drive one screw into each leg near a corner (The center of these pieces is to be drilled for the bolts.)

Place another 45 inch 2x4 three inches from the other end and repeat the above procedure. You now have one frame side that needs to be squared up before adding any more screws. You can use a framing square to square up the legs to the cross braces, or you can measure from the outside corner of one leg to the outside corner of the other leg at the opposite end. Make a note of the measurement. Swap the tape measure to the other leg and measure the same way. Adjust the legs until the measurements match and the frame is square. Add another screw to each end of your cross pieces to lock it in square.

Repeat with the other pair of legs.

Stand the two frames on end with one leg up, and attach a 48 inch piece to the ends of each 45 inch piece with deck screws. Also screw into each leg while you are there. Two screws into the ends of the 45 inch cross pieces and four screws into each leg. Once both pieces are attached flip the table over and repeat the process.

Add two more cross braces to the top and bottom shelves between the 48 inch pieces by placing them at 16 inches intervals. You now have the workbench frame completed.

Building your rolling workbench will now require cutting the OSB sheet into two 48 inch square pieces. Attach one to the top of your new workbench and cut a 3 5/8 inch square out of each corner of the other half to fit the bottom shelf. Fasten them down with the #8 x 1 ½ screws. If the workbench is slightly out of square you can put a screw in one corner, align the top to the next corner and put one screw there and then push the top into square and finish fastening it down.

Drill the four holes through the ends of the 45 inch pieces and the legs and bolt them together for added strength. Put a flat washer on a bolt and put it in the hole add a flat washer to the other end, then a lock washer, and finally a nut. Tighten them down with a wrench and a ratchet and socket.

The last thing we need to do to complete building a rolling workbench is to add the wheels. Flip the rolling workbench upside down and screw the wheels into the legs. Be sure to pair the swiveling wheels together on one side of the bench or it still will not turn.

There you have it a rolling workbench that will hold up to some serious use!