In 2014, a friend sent me a video of a guy (Paul Sellers) building a workbench in his backyard using only hand tools. I thought it was crazy and I was jealous at the same time. I wished I could do that. I kind of knew I would do it someday.
Years pass. In 2017, I'm starting to use hand tools more often. I print off the plans to the build the workbench but then I move houses and life happens.
Years pass. In 2021, I decide to make a chessboard by hand. I'm struggling to hold it securely as I plane it. I'm frustrated with working on top of my homemade table saw or over sawhorses. I find the workbench plans I printed in 2017. I'm serious this time.
2022. I want to build a better chessboard than the first one and I know the only way is to have a proper workbench with a proper vise and a proper place to put everything. That would be the only way to build a proper chessboard, properly.
So I started. Bought the wood, quick-release vise, and fasteners. Watched Paul's video series at every step.
I decided to use only hand tools to build the bench. Why? The challenge of it, hone my skills, and I was frustrated with my low end power tools.
Years pass. In 2017, I'm starting to use hand tools more often. I print off the plans to the build the workbench but then I move houses and life happens.
Years pass. In 2021, I decide to make a chessboard by hand. I'm struggling to hold it securely as I plane it. I'm frustrated with working on top of my homemade table saw or over sawhorses. I find the workbench plans I printed in 2017. I'm serious this time.
2022. I want to build a better chessboard than the first one and I know the only way is to have a proper workbench with a proper vise and a proper place to put everything. That would be the only way to build a proper chessboard, properly.
So I started. Bought the wood, quick-release vise, and fasteners. Watched Paul's video series at every step.
I decided to use only hand tools to build the bench. Why? The challenge of it, hone my skills, and I was frustrated with my low end power tools.
Remember, I just wanted to make a chessboard and maybe some small boxes. This workbench is designed to build furniture. I didn't want to make furniture. I wasn't thinking about furniture nor trying to learn to make furniture.
However, once the bench was almost complete, it hit me. This bench is like a piece of furniture. Oh my gosh I think I can make furniture. Wait a minute. I think I want to try to make furniture now.
It was a sort "wax on, wax off, but Mr. Miyagi, when will I learn Karate" moment. Paul Sellers had taught me karate without me even knowing it. (my first piece of "furniture")
However, once the bench was almost complete, it hit me. This bench is like a piece of furniture. Oh my gosh I think I can make furniture. Wait a minute. I think I want to try to make furniture now.
It was a sort "wax on, wax off, but Mr. Miyagi, when will I learn Karate" moment. Paul Sellers had taught me karate without me even knowing it. (my first piece of "furniture")
The bench continues to evolve to become even more of a joy to use.
Add-ons so far include:
Add-ons so far include:
- Cubby shelves on each end (one with sharpening tray shelf)
- Bottom shelf
- Large center drawer
- Castors
- Well board tool tray with kaizen foam
- Shooting board (the tool tray and shooting board can be stored on a rail on top of the drawer when not needed)
- Tail vise (7" wide vise reinforced to 9" wide
- Sliding bench light
Don't make the same mistakes.
The biggest mistake I made was I didn't fully understand the workbench design before I started. I used different dimensions of lumber than Paul, followed along in the video series, and trusted it would work out. At the end, I had to make the aprons longer (hang down farther) so the carriage bolt would clear the rail of the leg frame.
I later modeled the bench using Fusion360 (free for personal use) as a parametric model so anyone can open it, adjust the dimensions, and see how it will affect everything.
I later modeled the bench using Fusion360 (free for personal use) as a parametric model so anyone can open it, adjust the dimensions, and see how it will affect everything.
Workbench CAD model (free)
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Model parameters
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| paul_sellers_ultimate_workbench.f3d |