Let’s Enlarge the Workbench!

When we moved into the house years ago, there was no workbench. The previous owners had built a structure to hold two large trash cans. Hubby removed the trash cans and attached a 3′ x 5′ piece of plywood to the top. After years of use, I decided to replace it with a new piece of particle board. One of my sons attached it for me, laying it on top of the old surface. I loved having the workbench look so new and fresh! As you can see, though, the working surface was pretty small.

Original workbench

Garage cabinets

For years hubby has tried to get me motivated to organize the garage. Usually, I’m game to reorganize just about anything but I knew it would be a big project so I procrastinated starting it. That all changed when my son was getting ready to organize his garage and offered us his garage cabinets. He said he prefers open shelving and was going to be giving them away. I hesitated at first, again thinking about what a huge task it would be to prep for them, get them from his house to ours, and then get our garage back in shape. I mentioned it to hubby who jumped at the chance to finally get the garage organized! He was SO excited that I figured it was time to get it done. Below are the cabinets in my son’s garage.

Supplies Used

• 2 gallons of white semi-gloss water-based interior/exterior paint
• 1 gallon white drywall paint
• Paint roller & pan
• Extension rod for roller handle
• Preservawood oil-based sealer
• 3″ paintbrush
• 2′ x 5 1/2′ piece of particle board
• 20′ 2′ x 6′ (or 2′ x 4′) board
• Clamps
• 3″ star head screws
• Drill w/drill bit & screwdriver bit
• Level
• Skill saw
• Tape measure
• Miter saw

Step 1 – Prep space

We decided to move the shelving to the opposite wall. Once the shelving unit was moved, there were 2 additional feet between the end of the workbench and wall. With the extra space, I could increase the length of my workbench! At first, I thought I would do that by buying another piece of particleboard and set it on top of the existing workbench. If I did that, my workspace would be 3′ x 7′ instead of 3′ x 5′. After mulling it over, though, I decided to leave the existing 3′ x 5′ top and add an ‘arm’ to the bench; doing that would give me the 3′ x 7′ but also an additional 2′ x 2 1/2′ section to use. Before starting the construction of the new section (and before the cabinets arrived), I swept and vacuumed the space the painted the drywall.

Step 2 – Build base

Now that I had my dimensions – 2′ x 5 1/2′, my decision was just how to build the base. At first, I planned to construct a free-standing base similar to the existing base. I planned to use wood that I had on hand. I still have scrap wood from when we replaced the deck floor boards two years ago (even though I used most of them to build the pool deck this summer). However, after looking in my scrap pile and finding that I only had one piece that was at least 5 1/2″, my plan changed. Yes, I could have bought one 6′ board of either 2 x 4 or 2 x 6 but why not use what I had?

Instead of building a free-standing base, I decided to attach the support pieces to the two walls. I cut the pieces to the length I needed with my miter saw and secured them to the studs using 3″ brass screws. Below the cross piece on the beadboard wall, I attached two upright supports. Since I was working alone, I used clamps to hold the end pieces to a piece that would be the outer leg while I secured the boards with screws. Using the only long piece of wood that I had, I attached it to the support piece on the beadboard wall and leg. The last piece of the base was cross-support that was placed 18″ from the wall to hold a smaller piece of particleboard. This piece was attached with L brackets.

The base is not pretty but it is nice and solid! But, then, the old base is not pretty either 🙂

Step 3 – Attaching the top

For the top, I was also using scrap wood. I had a piece of particle board that was 2′ x 4′ and also a smaller piece. I used both of them to make the top. The cross-support I added was so I would have something to attach the two pieces where they met. The particleboard was also attached with screws. I am SO thrilled that the new section of the top was level with the existing workbench!

Step 4 – Seal particleboard

I decided to apply a water-resistant sealer to the particleboard because it wasn’t long after my son attached the previous piece of particleboard to my workbench before it got wet. Since particleboard and water do not mix, the spot that got wet left a big, ugly mark. This time, I wanted to try to prevent that from happening. Before adding sealer, I flipped the damaged section of particleboard over so it would look new. I had some Preserva Wood left from a previous project and applied it to the wood using a 3″ paintbrush. Preserva Wood is an oil-based sealer and the instructions are to use just one coat so I made sure to thoroughly cover the surface.

Finished workbench

I cannot believe how quick and easy it was to add this extension to the workbench! Since I had all the supplies on hand, this project was free or at least pre-paid!

Before, During, After

Instructions

• Using 2′ x 4′ or 2′ x 6′ boards, cut pieces for the base
• Attach support pieces on two walls using 3″ screws
• Using clamps to hold the cross board at the end of the bench & the leg, secure them together using screws
• Attach the last support piece to the support piece on the wall and the leg with screws
• Cut particleboard to width and length using a skill saw
• Attach particleboard to base using 2″ or 2 1/2″ screws
• Apply 1 coat of oil-based Preserva Wood to the surface of the particleboard with either a paintbrush or roller
  • Allow drying time before use

New cabinets!

Here is the finished look with the cabinets and new peg board! I’ll write about the organization and the peg board projects soon!

For your convenience

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