Secondary Bench / Cupboard Unit

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Project by MayflowerDescendant posted 03-31-2014 12:44 AM 1952 views 3 times favorited 8 comments Add to Favorites Watch

In addition to my main work bench (posted previously), I wanted a secondary work surface / bench with additional, cupboard-like storage, above and below. Here is what I came up with – designed to fit the wall space between my sheet good and lumber storage racks, and the side door of my shop.

The 1.75-inch thick bench top is 65-inches wide x 34-inches deep (and 38-inches high). It is wrapped in straight-grain douglas fir with a sacrificial, 0.25-inch thick masonite top. All cabinetry (above, below and drawer sides) is made from 0.75-inch cabinet grade ply. The only exceptions – the drawer and pullout tray bottoms are 0.5-inch ply – versus standard 0.25-inch ply – given the combined weight of the tools you can place in such large drawers.

The lower cupboard unit is 60-inches wide x 30-inches deep. The two top drawers are 26.5-inches x 26.5-inches and 4.5-inches deep, supported by 26-inch, 100-pound, full-extension slides (Lee Valley product number 02K3026). These drawers hold all of my cordless drill, drivers, batteries and chargers on one side, and all my brad nailers and staplers on the other side. As per the pictures, each cupboard features two pull-out trays designed to hold all of my sanders, routers, various saws (trim, circular, jig) and accesories (router fences, sliding shaper jib, etc.). Each tray is 26.5-inches wide x 24-inches deep, supported by 24-inch, 100-pound, full extension slides (LV 02K3024). The distance the trays are apart (height-wise), was deterimed by the height of the tools I was placing in the various trays. I laid out / grouped all my tools together to determine what those distances need to be. The drawer and pull out tray handles are brass plated handle pulls (LV 01W3610). The door hinges (upper and lower units) are brass plated, 0.5-inch wrap overlay (LV 00W2723)

The upper cupboard unit is 60-inches wide, 26-inches tall and 18-inches deep. As per the pictures, each side contains 1 dozen small storage containers for all those things were collect – from sharpening stones and jigs, through to commonly used hardware, etc. While I purchased handles for the cupboard doors, I liked the clean look of the doors (cut from the same sheet) without hardware on them.

After hanging the upper cupboards, there was still 21-inches between the top of the cupboard and the ceiling. Rather than simply pile stuff on top of the upper unit, I placed a cleat along the wall, cut, finished and fastened a 0.5-inch thick piece of ply (65-inches wide x 21-inches deep) and trimmed it in straight grain douglas fir. That shelf holds 4 large, flip-top storage containers of stuff. To support the front edge of this shelf, I fastened a strip across the ceiling, screwed it into the floor joists above, to which I secured 3 large eye-hooks and heavy-gauge wire from those hooks to 3 eye-bolts along the front of the shelf.

With the exception of the sacrificial masonite bench top, all surfaces are finished with 3 coats of Minwax`s Helmsman Spar Urethane, Clear Semi-Gloss.

I am very happy with the end result. The additional work surface is a blessing, but all that storage – above and below – is awesome!

All comments and questions are welcome.

-- Glen - Vancouver, British Columbia, Canada

8 comments so far

View TopamaxSurvivor's profile


20012 posts in 4646 days

#1 posted 03-31-2014 12:49 AM

Nice addition to the shop.

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View Karson's profile


35267 posts in 5370 days

#2 posted 03-31-2014 12:51 AM

Glen : A great job from an additional Mayflower Descendant.

We need to stick together there is a limited number of us.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View TopamaxSurvivor's profile


20012 posts in 4646 days

#3 posted 03-31-2014 12:55 AM

Might be more of us than meets the eye at first glance ;-))

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View mloy365's profile


448 posts in 4100 days

#4 posted 03-31-2014 11:35 AM

Great job. Very nice organization in your shop.

-- Mike - Northern Upper Michigan

View Roger's profile


21047 posts in 3774 days

#5 posted 03-31-2014 12:39 PM

Really nice and lotsa storage.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View WebErika's profile


104 posts in 2499 days

#6 posted 04-01-2014 04:57 AM

All those labels and shelves and cabinets … one can only aspire to be so organized! Really nice job.

-- Have a happy day!

View Fishinbo's profile


11362 posts in 3145 days

#7 posted 04-07-2014 01:48 PM

Wow! Awesome bench and cabinets! Additional storage for great organization in the shop, very functional builds. Excellent job!

View helluvawreck's profile


32122 posts in 3836 days

#8 posted 04-07-2014 02:14 PM

This is very nice work. Congratulations.

helluvawreck aka Charles

-- helluvawreck aka Charles,

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