Thread: (Beginner) Making Workbench from pallets, tips from others needed.

John Heisz just published some plans for a workbench here. While his workbench is all drawers, it shouldn't be too hard to modify the plans to suit your requirements, particularly because John has specifically designed it to be simple to build.

I am not trying to be a wet blanket, although I would not attempt to make a workbench from pallets especially if I did not have a bench and a vice, you will need to be able to dress the timber, cut it square
and to length repeatably, depending on what other tools/machinery you have this could prove vary problematic. I suggest you find a source of quality recycled timber that is already dressed and straight.
When you have a quality bench working with dubious quality pallets will be a lot easier, something to be aware of, many pallets these days are treated with nasty chemicals.

Find a fire door from a skip, and work to that ...ie use it as a reference, as it will be suitable to
plane on, if you make it secure, for the time being.
Dont affix it down so tight as to flex this fire door because its...
1 rigid (won't deflect if supported correctly)
2 flat, (necessary for learning hand planing with speed, ease, precision and understanding), gained by
not by watching and repeating, someone planing timber using a vise, and just matching two pieces together, thats for building sites that kinda thing.
3 stable, (as in it wont warp as you can get with solid timber contracting or expanding), more,so with softwoods, but that can be even more problematic if you fasten it with screws, nails, or dowels without any sort of planning ... so its common to have brackets instead with slots in them to account for this movement,
I ain't got time for dat, actually I do, and am going to much trouble selecting iroko for a Frank Klausz bench, so I can chop mortises on, and
have loads of handy things, but until then I will be using this top.
I would have gone mental if I had some carp bench to try and make this bench on, it would be near impossible.

Like for planing on, it really needs to be flat, it looks dandy on utube, but when you have to assemble components, errors add up, and if theirs
any long pieces your working on it can be really out.
So treat that firedoor with respect and it will look after you, I use a composite material, but before that I planed to use the fire door I have.
Clamp a batten on it for planing on and get a nice Stanley no. 5 1/2(with a thick sole, not lapped by an oaf) and go to town.
Get an angle poise lamp for planing, as you get it down and can shine the light under the timber, "candling" this is called, with the intention of seeing no light after removing high spots. there should be no rocking atall either...
Most folks planing timber in a vise don't show that on youtube.
Loads of other things thats only possible with a flat bench, that I wont get into.

Mainly the big test is getting two lengths the same length as your entire bench, planing them down to exactly the match the bench top and placing them togther...
If they don't match perfectly, the bench isin't flat. shim and try again
Good luck
witness marks.JPGSAM_2350.jpgSAM_2351.JPGSAM_1390.JPGSAM_2432.JPG

Originally Posted by Widget1983

I'm wanting to make it out of recycled material. In this case, mostly pallets.

download.jpg

Does anyone have any suggestions on how to tackle this.. or know where I can find some plans similar to this design ?

Thanks in advance

Sounds like an interesting challenge. If you braced the design you pictured better it will work . It needs diagonal braces in the three frames and Two at the back . You could probably do exactly that design except for the four long lengths needed to tie it together. Buy them . As for plans , you need to measure the common components that come from a pallet and work from there at how you could make it with Nails and bugle screws.
Rob

Hey guys, terribly sorry for the late reply. :/

John Heisz just published some plans for a workbench here. While his workbench is all drawers, it shouldn't be too hard to modify the plans to suit your requirements, particularly because John has specifically designed it to be simple to build.

Thanks mpot

Originally Posted by China

I am not trying to be a wet blanket, although I would not attempt to make a workbench from pallets especially if I did not have a bench and a vice, you will need to be able to dress the timber, cut it square
and to length repeatably, depending on what other tools/machinery you have this could prove vary problematic. I suggest you find a source of quality recycled timber that is already dressed and straight.
When you have a quality bench working with dubious quality pallets will be a lot easier, something to be aware of, many pallets these days are treated with nasty chemicals.

Thanks China . That's understandable, though I as hoping to make this completely from salvaged timber (not just pallets, I probably should have worded my topic better ). It probably won't be great, but if it's functional and sturdy, I'll be happy ... at least until I get/build something better

Tools and machinery, not a whole lot tbh. I don't have a mitre saw, but I have access to a Circular Saw (not sure on blade size). I was just going to clamp a straight edge to use as a guide, which should still be ok ? Other than that, I have the usual, drills, hammer etc..

Originally Posted by Tom trees

Find a fire door from a skip, and work to that ...

Mainly the big test is getting two lengths the same length as your entire bench, planing them down to exactly the match the bench top and placing them together...
If they don't match perfectly, the bench isin't flat. shim and try again
Good luck

Thanks Tom , Ill keep an eye out for a fire door, though tbh, I don't think I would come across one, at least in my area lol. With the timber lengths, you're right, that would be a challenge :/... would it be possible to make the centre support leg thicker, then use a double sided lap joint with 2 separate pieces, rather than one long one ?

Originally Posted by auscab

If you braced the design you pictured better it will work . It needs diagonal braces in the three frames and Two at the back . You could probably do exactly that design except for the four long lengths needed to tie it together. Buy them . As for plans , you need to measure the common components that come from a pallet and work from there at how you could make it with Nails and bugle screws.
Rob

Thanks Aus , do you mean something like this ?

download2.jpg

with the larger cross support running on that back (not front like in pic :P)

I'll have to head outside and measure the space needed, though probably the parts I'm still thinking about it,

1. Best way to make the drawers. I was planning on just have them slide in/out https://youtu.be/S04VfbPzXRU

2. What Joints to use. having limited tools, I think I'm really going to be limited to what I can do. Being a basic workbench, I may have to butt joint them and screw them into the legs (which I'll probably go for a thicker set.. i.e. 4x4 instead of 2x4)


Understandably, this project isn't probably the quality everyone's into, though any and all tips are muchly appreciated

Yeah , that’s it with the bracing . It’ll make a big difference as to how long the bench lasts and stands up to hard work . You could do it with wood or there is Gal strap builders use for the same thing in roofs and walls . I would also make sure the long cross members on the front are fixed and glued well and clean on the inside corners so corner blocks can be added, they will help a bit with the bracing of the front.
I like Matthias‘s router mortising gizmo !
I did a lot of workshop drawers , all just nailed up which is what I assume you would do for a pallet bench . Some I rebated the back of the drawer front for the sides, others I nailed them up and added the bottom then glued on a false front . The rebates would have been the quickest . It was just about not seeing the drawer side ends in the finished piece .

Aus
I mean Rob

I think it's a great plan to build a workbench out of (clean) junk lumber. What's the work bench for?
My greatest puzzle with pallets is how to pull the spiral nails. K.I.S.S.
Then, I have a good enough bench to get me up off the dirt so I can build a good work bench.

Originally Posted by Robson Valley

I think it's a great plan to build a workbench out of (clean) junk lumber. What's the work bench for?
My greatest puzzle with pallets is how to pull the spiral nails. K.I.S.S.
Then, I have a good enough bench to get me up off the dirt so I can build a good work bench.

Thanks , I like the idea of re-use/recycling. Seems we live in a more 'throw away' world these days :/. At the moment, I like to tinker with small projects, like stripping down/rebuild lawnmowers (especially older ones). I like the idea of taking something not working/worn out, and bringing some life back into it.
Much of what I'd use the bench for, isn't too heavy, more-so just a bench to have some space to work on. I'm using a short plastic table at the moment, which 'works', but could be a lot better, such as a bit higher, and wider, with some sort of 'lip' to help prevent things from rolling off the edge.
I also considered installing an old kitchen/laundry sink into one end, with a drum of cleaning solution under it for a cleaning station... but with the width of the bench I'm looking at making, there might not leave much room, so maybe an extension/portable cleaning bench down the track.

I think most of the pallets we have around here are just held together with normal wood nails, so should be fairly easy to pull a part. Not sure how much of the pallet I'd use, after looking into it, maybe use for making the drawers, and maybe table top, but I've been looking at scrap timber from wood places too, hoping to come across something i can use.

Main problem for me is, working out the best method of joining it all together, based on the tools I have access too, but I'll work that out when It come time to build/design

On another note, are there any good programs to use where I can design/draw up a plan, with different joints etc.. to see how it looks, if there's issues, etc.. ??

I use a Harmann PP38+ wood pellet stove to heat my entire house for winter. 2 x 1200 sqft to 70F
That takes an average of 10,000lbs of ultra dry, compressed wood pellets for fuel each winter, about 1/2 the cost of furnace oil.
The pellets arrive as 50 x 40lb bags at a time on a fresh new clean SPF pallet. We grow pallets here.



Anyway, that gives me 5 fresh new freight pallets every winter to play with.
There's only so much a guy can do with them after 10+ winters!

Protowork bench was a back saver.
3 specialist wood carving benches ( maybe a pallet each?)
4 outdoor back yard benches for rough work, stone carving, etc.
3 benches in the vegetable garden to rest my weary butt.

Yes, all of the benches are crude. Yes, they are vulnerable to attack ( chainsaw. oooops).
Most of the benches weather the elements and I don't care. Temps this year have swung from +47C to -32C.
Right now, we are up to our whazoos in fresh snow, about 3' in the last 2 weeks. and, -25C nights with it.

I think the deal is to get the height right for the job. Desk top, kitchen top, lab bench top.
My best heavy duty wood carving bench for story poles is only 18" high.
That puts the carving in my face when I lean over on a gouge.
Next, don't fall in love with the bench. It's the magnificent stuff that comes off your benches that matters.