How to build a 96" Garage Workbench with Glued Pocket Joints

Cut list

Step by step

1. Prepare edges and pull holes

   Smooth the prepared parts and drill the pull holes before assembly.

   • Label matching cabinet and drawer pieces on their hidden faces.
   • Clamp each drawer front over a sacrificial backing board.
   • Drill the 2 pull holes with a 3/16" bit.
   • Sand exposed surfaces with 120-grit discs.
   • Ease sharp edges with 180-grit discs.

2. Drill the concealed pockets

   Test the Kreg settings on matching offcuts and drill every pocket before assembly.

   • Clamp the Kreg jig to supported matching offcuts.
   • Set the drill collar using the jig maker's thickness chart.
   • Test each screw length in a clamped scrap joint.
   • Mark pocket rows on the hidden faces shown in the proposal.
   • Drill the pockets with the cordless drill and Kreg stepped bit.
   • Clear chips from every pocket and mating edge.

3. Assemble the on-edge rectangle

   Glue and pocket-screw the on-edge rectangle with exactly four internal braces.

   • Stand the front and rear rails on their 1 1/2" edges.
   • Spread a thin glue film on the end rails and brace ends.
   • Clamp the 2 end rails between the long rails.
   • Space the 4 internal braces evenly between the end rails.
   • Match the rectangle's diagonal measurements.
   • Drive 2 pocket screws of 2 1/2" length at each transverse-member end.

4. Fit the continuous platform

   Glue, fasten, and trim one plywood sheet over the rectangle and its four braces.

   • Support the frame level on low sacrificial supports.
   • Spread a thin glue film over the frame's upper edges.
   • Fasten the whole plywood sheet to every frame member.
   • Mark a 94" × 25" outline from the framing beneath the sheet.
   • Clamp a straightedge guide alongside each marked edge.
   • Trim each edge with the circular saw from an open sheet edge.

5. Mount cabinets on the platform

   Glue and pocket-screw both cabinet shells and their bottom edges to the platform.

   • Spread glue on each cabinet back's side edges.
   • Clamp each back square between its matching sides.
   • Drive the 1 1/4" pocket screws from the cabinet interior.
   • Spread glue on the side and back bottom edges.
   • Clamp both cabinets flush with the platform ends, front, and rear.
   • Drive the bottom pocket screws downward into the platform.

6. Join the cabinet pedestals

   Glue and pocket-screw the unchanged center supports between the cabinets.

   • Position the platform assembly on the intended dry, level floor.
   • Verify the clear distance between cabinets is 34".
   • Spread glue on the rear-panel and front-rail ends.
   • Clamp the rear panel flush with the cabinet tops and backs.
   • Clamp the front rail with its underside 27 1/8" above the floor.
   • Drive 1 1/4" pocket screws into the dividers from the prepared pockets.

7. Install the double worktop

   Attach the lower top with glued pocket joints and the replaceable upper top from underneath.

   • Spread glue on the cabinet side and back top edges.
   • Lift the lower worktop onto the cabinets with a helper.
   • Align the top with 1" end overhangs and 1 1/2" front and rear overhangs.
   • Drive the 1 1/4" pocket screws upward into the lower worktop.
   • Clamp the unglued upper layer flush with the lower layer.
   • Drive the 1 1/4" flat-head screws upward from the lower layer.

8. Assemble the nine drawer boxes

   Glue and pocket-screw all nine 1/2" plywood boxes without changing their dimensions.

   • Spread glue on each front and back end edge.
   • Clamp the front and back square between their matching sides.
   • Drive the 1" corner pocket screws from the end panels into the sides.
   • Spread glue over the four lower wall edges.
   • Clamp the bottom flush with all four outside box edges.
   • Drive the 1" bottom pocket screws downward from inside the box.

9. Fit the fronts and pulls

   Center the graduated inset faces on their boxes and attach the pulls.

   • Center each face across its matching drawer box.
   • Position the face bottom 1/2" below the underside of the box bottom.
   • Clamp the face firmly against the box front.
   • Drive the 1" mounting screws from inside the box.
   • Seat each pull over its two drilled holes.
   • Tighten the matching machine screws from the back of the face.

10. Seal the wood surfaces

    Remove glue residue and protect the workbench before fitting the slides.

    • Sand away dried glue residue with the random orbital sander.
    • Remove sanding dust from all exposed surfaces.
    • Mask the pulls against finish splashes.
    • Apply the first thin coat of water-based polyurethane.
    • Apply the remaining coats at the maker's stated intervals.
    • Allow the finish to cure before mounting slides.

11. Install slides and test drawers

    Mount all nine slide pairs, adjust the faces, and check the center storage bay.

    • Mark each cabinet slide line level with its drawer side's center.
    • Set each cabinet member back 7/8" from the cabinet front edge.
    • Fasten each cabinet member through its slots with #8 × 5/8" pan-head screws.
    • Fasten each drawer member flush with the box front using #6 × 1/2" pan-head screws.
    • Adjust each inserted drawer until the face gaps are even.
    • Drive the remaining screws to complete 4 screws per member.