2x4 Workbench w/ Shoplight and Peg Board

This plan is adapted from the Kreg Jig website but I added a peg board, a shop light, and caster wheels.

Find the original plan here: www.kregtool.com/images/icons/2x4_bench.pdf

Tools Needed:

1. Circular Saw
2. Miter Saw
3. Jig Saw
4. Drill
5. Right Angle Clamp
6. Face Clamp
7. Kreg Jig (Pocket Screw Jig)

Hardware & Non-Wood Materials:

1. 50 -2 1/2” #8 Coarse, Pocket Hole Screws
2. 100 – 1 1/4” #8 Coarse, Pocket Hole Screws
3. 1 Bottle of Wood Glue – Optional
4. 4 – 6” Casters (Suggestion of 2 locking wheels)
5. 2 – Shelf Brackets
6. 25 – 5/16” Lag Screws
7. 1 – Shop Light
8. 2 – Fluorescent Bulbs
9. 1 – Surge Strip
10. 2 – Garden Pot Hooks
11. 25 – 1 1/4” Wood Screws

Wood Shopping List:

1. 3 - 2'x4' x 3/4” - MDF Panel
2. 1 – 4'x8' x 1/4” - Peg Board
3. 7 – 2'x4' x 8' – 2 by 4's

Cut List:

Part #	Length	Width	Thicknesss
Part A – 2 Legs (short)	28”	3 1/2”	1 1/2”
Part B – 2 Legs (long)	72”	3 1/2”	1 1/2
Part C – 4 Long Rails	37”	3 1/2”	1 1/2”
Part D – 4 End Rails	19 1/2”	3 1/2”	1 1/2”
Part E – 2 Top *2x4 notches are required to but up to the back uprights	48”	24”	3/4” *
Part F – 1 Shelf	44”	22 1/2”	3/4”
Part G – 1 Peg Board	42”	44”	1/4”

Let's take a look at how I did this project:

• First, safety. Wear safety goggles and ear protection when using saws and drills.
• Layout your 2x4 and cut them with the Miter Saw (A Circular Saw will work, too)
• Look at Figure 1 to see the Cut List Lay out

• Drill your pocket holes for your 2x 4 joints

• Set your jig to drill 2x4 or 1 1/2” thickness
• Drill the Long Rail (37” Long)
• Drill the Short Rail (19.5” Long)
• Look at Figure 2 for the location of the holes.

• Next Drill your shelf and top shelf pocket holes

• Set your jig to drill 3/4” on the Kreg Jig (Don't forget to set your drill bit, you will destroy your jig and drill into the base)
• Drill the long rails, leave 6” between each drill hole (6 holes) (make sure you drill the holes on the same face as the prior holes)
• Drill the short rails leave 4” between each drill hole (4 holes)

• Look at Figure 2 for assistance
• Now put your front brace together (join 28” legs with the 37” rails, use your clamps to align the joints) See Figure 2
• Now put your 72” Legs and 37” rails together. Make sure that you put the rails at 28” from the bottom to match the front.
• Join the front with the back by using the 90 degree clamp to join the 19 1/2in pieces to the front (Additional hands might be helpful here)

• Add the caster wheels. To do this you will use the lag scews to attach the wheels. You need to cut wood blocks to attach to add the fourth lag screws. 

• Add the shelf , but first you need to rip 1 sheet of the MDF to 44” long and 22 ½ in wide. First rip the shelf to 22 ½ in wide. Keep that piece for later. Now cut the length to 44” long.

• Now notch a 2x4 (1 ½ in x 3 ½ in) on each corner
• Place the shelf on the unit

• Take your clamp, clamp your shelf and use the 1 ¼ in pocket screw to attach the shelf
• Now it's time to make the top shelf
• From two inches on the outside of the back edge make a 2x4 notch ( 1 ½ in x 3 ½ in) – these notches will allow you to put the butt the top up with the 2x4 legs in the back.
• Repeat for the second piece

• Use 1 ¼ in pocket screws to attach the first top piece. Screw it on tight
• Add the second piece with screws (or wood glue if you like). Screw it on tight as well.
• Okay, do you remember that board that was left from riping the shelf? Drill pocket holes on that board (¾ in settings) use the 1 ¼ pocket hole screws to butt this up against the rail to give your bench a backing plate.
• Add supports for your lights (shelf brackets). Use your lag screws to attach it to the board

• Take your shop light out – (put up without bulbs in). Put the plant hooks through the holes in the shelf bracket, then hook the chain on the shop light up, to the desired heigh
• Now take your peg board and rip it to 44” by 42”. Use your wood screws and attach the peg board to the back of the tall legs.

• Now take your surge strip and place it between your splash board and peg board. Then drill holes on each side of the peg board to add eletrical items (chargers, shop light, etc)

• Now add peg hooks and accessories to help organize your board (I picked up about $20 at Wal-mart)
• Enjoy – for work and organize