How to build a JDB Workstation with Easier Three-Piece Lower Shelves

Cut list

Step by step

1. Shape the open shelf notches

   Shape open-edge leg notches in the three precut panels for each lower shelf.

   • Mark the edge notches from each panel's dimensioned template.
   • Clamp each panel on supports clear of the notch outlines.
   • Saw the open notches from the panel edges with a jigsaw.
   • Sand the notch edges smooth.
   • Arrange each set of three panels flat with its seams touching.
   • Test the paired-leg offcuts in the assembled openings.

2. Smooth the exposed edges

   Sand the precut parts and check an actual tote before assembling the revised workstation.

   • Inspect the precut boards and plywood for damage.
   • Sand exposed edges with 120-grit abrasive.
   • Ease the worktop corners without rounding the mating faces.
   • Remove sanding dust with a clean cloth.
   • Test a sample tote against a pair of runner offcuts.

3. Pair the main bench legs

   Assemble the paired 2x4 legs for the main repair bench.

   • Pair the matching leg boards with their ends flush.
   • Clamp each pair flat against a straight assembly surface.
   • Drill clearance holes through the first board at the indicated positions.
   • Drill pilot holes into the second board.
   • Drive 2 screws through each leg pair.

4. Attach the lower rails

   Assemble the retained lower frame before adding the shelf seam supports.

   • Mark the lower rail top edges 10" above the leg bottoms.
   • Clamp the lower rails to the marks.
   • Square the frame on a level assembly surface.
   • Drill the indicated pilot and clearance holes.
   • Drive 2 screws through each rail-to-leg contact.

5. Add the lower center support

   Install the existing lower center rail before adding the seam cleats.

   • Center the support between the lower long rails.
   • Clamp its top flush with the perimeter rails.
   • Drill pilot and clearance holes through the long rails.
   • Drive 2 screws into each support end.

6. Support the shelf seams

   Add four flat 2x4 cleats behind the lower long rails to support the new shelf seams.

   • Position two flat cleats inside each lower long rail.
   • Clamp each cleat between a leg and the center support.
   • Align all cleat tops with the rail tops at 10".
   • Drill the marked pilot and countersunk clearance holes through the long rails.
   • Drive 2 recessed 3" screws into each cleat.

7. Fit the three shelf panels

   Fit the middle panel and two narrow edge strips around the legs without threading a full shelf over them.

   • Lower the 22" middle panel between the front and rear legs.
   • Slide the 3" front and rear strips around the legs onto the supports.
   • Align the panel edges flush with the outside frame.
   • Butt both seams tightly with their surfaces flush.
   • Drill the marked pilot and countersunk clearance holes.
   • Fasten all three panels with recessed 2" screws.

8. Attach the upper rails

   Attach the upper perimeter rails of the main repair bench.

   • Clamp the upper rails flush with the leg tops.
   • Check the outside frame size of 58" × 28".
   • Drill pilot and clearance holes at the indicated staggered positions.
   • Drive 2 screws through each rail-to-leg contact.

9. Add the upper center support

   Install the centered upper support without changing its baseline position or connections.

   • Center the cross support between the upper long rails.
   • Clamp the support top flush with the perimeter rails.
   • Drill pilot and clearance holes through the long rails.
   • Drive 2 screws into each support end.

10. Fit the lighting uprights

    Attach only the two lighting uprights, leaving the bench back open.

    • Square the frame until its diagonals match.
    • Clamp the two tall uprights against both rear rails.
    • Drill the indicated staggered pilot and clearance holes.
    • Drive 4 screws through each upright at each rail.
    • Check both uprights for plumb.

11. Pair the module legs

    Assemble the paired 2x4 legs for the additional repair bench.

    • Pair the matching leg boards with their ends flush.
    • Clamp each pair flat against a straight assembly surface.
    • Drill clearance holes through the first board at the indicated positions.
    • Drill pilot holes into the second board.
    • Drive 2 screws through each leg pair.

12. Attach the lower rails

    Assemble the retained lower frame before adding the shelf seam supports.

    • Mark the lower rail top edges 10" above the leg bottoms.
    • Clamp the lower rails to the marks.
    • Square the frame on a level assembly surface.
    • Drill the indicated pilot and clearance holes.
    • Drive 2 screws through each rail-to-leg contact.

13. Add the lower center support

    Install the existing lower center rail before adding the seam cleats.

    • Center the support between the lower long rails.
    • Clamp its top flush with the perimeter rails.
    • Drill pilot and clearance holes through the long rails.
    • Drive 2 screws into each support end.

14. Support the shelf seams

    Add four flat 2x4 cleats behind the lower long rails to support the new shelf seams.

    • Position two flat cleats inside each lower long rail.
    • Clamp each cleat between a leg and the center support.
    • Align all cleat tops with the rail tops at 10".
    • Drill the marked pilot and countersunk clearance holes through the long rails.
    • Drive 2 recessed 3" screws into each cleat.

15. Fit the three shelf panels

    Fit the middle panel and two narrow edge strips around the legs without threading a full shelf over them.

    • Lower the 22" middle panel between the front and rear legs.
    • Slide the 3" front and rear strips around the legs onto the supports.
    • Align the panel edges flush with the outside frame.
    • Butt both seams tightly with their surfaces flush.
    • Drill the marked pilot and countersunk clearance holes.
    • Fasten all three panels with recessed 2" screws.

16. Attach the upper rails

    Attach the upper perimeter rails of the additional repair bench.

    • Clamp the upper rails flush with the leg tops.
    • Check the outside frame size of 58" × 28".
    • Drill pilot and clearance holes at the indicated staggered positions.
    • Drive 2 screws through each rail-to-leg contact.

17. Add the upper center support

    Install the centered upper support without changing its baseline position or connections.

    • Center the cross support between the upper long rails.
    • Clamp the support top flush with the perimeter rails.
    • Drill pilot and clearance holes through the long rails.
    • Drive 2 screws into each support end.

18. Pair the module legs

    Assemble the paired 2x4 legs for the corner computer desktop.

    • Pair the matching leg boards with their ends flush.
    • Clamp each pair flat against a straight assembly surface.
    • Drill clearance holes through the first board at the indicated positions.
    • Drill pilot holes into the second board.
    • Drive 2 screws through each leg pair.

19. Attach the lower rails

    Assemble the retained lower frame before adding the shelf seam supports.

    • Mark the lower rail top edges 10" above the leg bottoms.
    • Clamp the lower rails to the marks.
    • Square the frame on a level assembly surface.
    • Drill the indicated pilot and clearance holes.
    • Drive 2 screws through each rail-to-leg contact.

20. Add the lower center support

    Install the existing lower center rail before adding the seam cleats.

    • Center the support between the lower long rails.
    • Clamp its top flush with the perimeter rails.
    • Drill pilot and clearance holes through the long rails.
    • Drive 2 screws into each support end.

21. Support the shelf seams

    Add four flat 2x4 cleats behind the lower long rails to support the new shelf seams.

    • Position two flat cleats inside each lower long rail.
    • Clamp each cleat between a leg and the center support.
    • Align all cleat tops with the rail tops at 10".
    • Drill the marked pilot and countersunk clearance holes through the long rails.
    • Drive 2 recessed 3" screws into each cleat.

22. Fit the three shelf panels

    Fit the middle panel and two narrow edge strips around the legs without threading a full shelf over them.

    • Lower the 22" middle panel between the front and rear legs.
    • Slide the 3" front and rear strips around the legs onto the supports.
    • Align the panel edges flush with the outside frame.
    • Butt both seams tightly with their surfaces flush.
    • Drill the marked pilot and countersunk clearance holes.
    • Fasten all three panels with recessed 2" screws.

23. Attach the upper rails

    Attach the upper perimeter rails of the corner computer desktop.

    • Clamp the upper rails flush with the leg tops.
    • Check the outside frame size of 28" × 28".
    • Drill pilot and clearance holes at the indicated staggered positions.
    • Drive 2 screws through each rail-to-leg contact.

24. Add the upper center support

    Install the centered upper support without changing its baseline position or connections.

    • Center the cross support between the upper long rails.
    • Clamp the support top flush with the perimeter rails.
    • Drill pilot and clearance holes through the long rails.
    • Drive 2 screws into each support end.

25. Pair the module legs

    Assemble the paired 2x4 legs for the inward return workbench.

    • Pair the matching leg boards with their ends flush.
    • Clamp each pair flat against a straight assembly surface.
    • Drill clearance holes through the first board at the indicated positions.
    • Drill pilot holes into the second board.
    • Drive 2 screws through each leg pair.

26. Attach the lower rails

    Assemble the retained lower frame before adding the shelf seam supports.

    • Mark the lower rail top edges 10" above the leg bottoms.
    • Clamp the lower rails to the marks.
    • Square the frame on a level assembly surface.
    • Drill the indicated pilot and clearance holes.
    • Drive 2 screws through each rail-to-leg contact.

27. Add the lower center support

    Install the existing lower center rail before adding the seam cleats.

    • Center the support between the lower long rails.
    • Clamp its top flush with the perimeter rails.
    • Drill pilot and clearance holes through the long rails.
    • Drive 2 screws into each support end.

28. Support the shelf seams

    Add four flat 2x4 cleats behind the lower long rails to support the new shelf seams.

    • Position two flat cleats inside each lower long rail.
    • Clamp each cleat between a leg and the center support.
    • Align all cleat tops with the rail tops at 10".
    • Drill the marked pilot and countersunk clearance holes through the long rails.
    • Drive 2 recessed 3" screws into each cleat.

29. Fit the three shelf panels

    Fit the middle panel and two narrow edge strips around the legs without threading a full shelf over them.

    • Lower the 22" middle panel between the front and rear legs.
    • Slide the 3" front and rear strips around the legs onto the supports.
    • Align the panel edges flush with the outside frame.
    • Butt both seams tightly with their surfaces flush.
    • Drill the marked pilot and countersunk clearance holes.
    • Fasten all three panels with recessed 2" screws.

30. Attach the upper rails

    Attach the upper perimeter rails of the inward return workbench.

    • Clamp the upper rails flush with the leg tops.
    • Check the outside frame size of 58" × 28".
    • Drill pilot and clearance holes at the indicated staggered positions.
    • Drive 2 screws through each rail-to-leg contact.

31. Add the upper center support

    Install the centered upper support without changing its baseline position or connections.

    • Center the cross support between the upper long rails.
    • Clamp the support top flush with the perimeter rails.
    • Drill pilot and clearance holes through the long rails.
    • Drive 2 screws into each support end.

32. Assemble the left tote frame

    Build the four-upright tote frame with its retained raised crown.

    • Lay the matching uprights on a protected assembly surface.
    • Clamp the top caps flush with the outer upright faces.
    • Check for 24" between the left and right upright faces.
    • Drill the indicated pilot and clearance holes.
    • Drive 2 screws through each cap into each upright.

33. Add the missing top runners

    Install the retained four runner pairs plus the top 1x2 pair so four totes can slide by their rigid rims.

    • Mark runner bottoms at 0", 17 1/2", 35", 52 1/2" and 70".
    • Clamp all five opposing pairs level with their marks.
    • Drill pilot and clearance holes at both ends of every runner.
    • Drive 2 recessed 2" screws through each runner-to-upright contact.
    • Test an empty tote by its rigid rim on each of the upper four pairs.
    • Check the fourth tote below the top pair through its full travel.

34. Tie the rear uprights together

    Install the five retained rear tie rails and check the fourth tote beneath the upper rail.

    • Square the tower until the rear diagonals match.
    • Clamp the five rear tie rails against the rear uprights.
    • Drill the indicated pilot and clearance holes.
    • Drive 2 screws into each rear upright at every tie rail.
    • Stand the empty tower upright with a helper.
    • Test the top tote lid beneath the upper rear tie.

35. Add storage above the totes

    Fasten the retained continuous plywood storage shelf above the caps without blocking tote entry.

    • Position the plywood above both caps with a helper.
    • Align its front and side edges flush with the frame.
    • Clamp the panel securely to the caps.
    • Drill the indicated pilot and countersunk clearance holes.
    • Drive 4 recessed 2" screws into each cap.

36. Assemble the right tote frame

    Build the four-upright tote frame with its retained raised crown.

    • Lay the matching uprights on a protected assembly surface.
    • Clamp the top caps flush with the outer upright faces.
    • Check for 24" between the left and right upright faces.
    • Drill the indicated pilot and clearance holes.
    • Drive 2 screws through each cap into each upright.

37. Add the missing top runners

    Install the retained four runner pairs plus the top 1x2 pair so four totes can slide by their rigid rims.

    • Mark runner bottoms at 0", 17 1/2", 35", 52 1/2" and 70".
    • Clamp all five opposing pairs level with their marks.
    • Drill pilot and clearance holes at both ends of every runner.
    • Drive 2 recessed 2" screws through each runner-to-upright contact.
    • Test an empty tote by its rigid rim on each of the upper four pairs.
    • Check the fourth tote below the top pair through its full travel.

38. Tie the rear uprights together

    Install the five retained rear tie rails and check the fourth tote beneath the upper rail.

    • Square the tower until the rear diagonals match.
    • Clamp the five rear tie rails against the rear uprights.
    • Drill the indicated pilot and clearance holes.
    • Drive 2 screws into each rear upright at every tie rail.
    • Stand the empty tower upright with a helper.
    • Test the top tote lid beneath the upper rear tie.

39. Add storage above the totes

    Fasten the retained continuous plywood storage shelf above the caps without blocking tote entry.

    • Position the plywood above both caps with a helper.
    • Align its front and side edges flush with the frame.
    • Clamp the panel securely to the caps.
    • Drill the indicated pilot and countersunk clearance holes.
    • Drive 4 recessed 2" screws into each cap.

40. Add the pegboard mounting rails

    Attach three horizontal 2x4 mounting rails to the main bench's tall rear uprights.

    • Mark rail bottoms 37 1/2", 49 1/2" and 61 1/2" above the floor.
    • Clamp all three mounting rails level against the upright fronts.
    • Drill the indicated pilot and clearance holes.
    • Drive 2 screws through each rail into each upright.

41. Install the plywood worktop

    Install two precut plywood layers on the main repair bench.

    • Clamp the lower plywood layer with a 1" overhang around the frame.
    • Check the frame diagonals before fastening.
    • Drill the marked pilot and countersunk clearance holes.
    • Fasten the lower layer to all five upper rails with 2" screws.
    • Clamp the upper plywood layer flush with the lower layer.
    • Fasten the upper layer with pilot-drilled, recessed 1 1/4" screws.

42. Install the plywood worktop

    Install two precut plywood layers on the additional repair bench.

    • Clamp the lower plywood layer with a 1" overhang around the frame.
    • Check the frame diagonals before fastening.
    • Drill the marked pilot and countersunk clearance holes.
    • Fasten the lower layer to all five upper rails with 2" screws.
    • Clamp the upper plywood layer flush with the lower layer.
    • Fasten the upper layer with pilot-drilled, recessed 1 1/4" screws.

43. Fit the plywood corner desktop

    Install two precut plywood layers on the corner computer desktop.

    • Clamp the lower plywood layer with a 1" overhang around the frame.
    • Check the frame diagonals before fastening.
    • Drill the marked pilot and countersunk clearance holes.
    • Fasten the lower layer to all five upper rails with 2" screws.
    • Clamp the upper plywood layer flush with the lower layer.
    • Fasten the upper layer with pilot-drilled, recessed 1 1/4" screws.

44. Install the plywood worktop

    Install two precut plywood layers on the inward return workbench.

    • Clamp the lower plywood layer with a 1" overhang around the frame.
    • Check the frame diagonals before fastening.
    • Drill the marked pilot and countersunk clearance holes.
    • Fasten the lower layer to all five upper rails with 2" screws.
    • Clamp the upper plywood layer flush with the lower layer.
    • Fasten the upper layer with pilot-drilled, recessed 1 1/4" screws.

45. Connect the inward workbench return

    Join the additional straight workbench to the corner desktop and the inward-facing return.

    • Position the additional workbench to the right of the right tote tower.
    • Position the corner desktop against the additional workbench's right end.
    • Position the return toward the operator side of the corner desktop.
    • Align the adjoining work surfaces flush.
    • Clamp the 2" seam cleats beneath both seams between the frames.
    • Drive pilot-drilled 2" screws upward into the lower plywood layers.

46. Connect the flanking tote towers

    Align the flanking tote towers with the benches using the retained lower-plywood-edge connections.

    • Position one tote tower against each end of the main repair bench.
    • Align the tower fronts with the main bench front.
    • Clamp the right tower against the additional workbench.
    • Mark the exact center of the lower plywood edge on each contacting upright.
    • Drill clearance holes through the uprights and pilots into the plywood edges.
    • Drive one alignment screw through each contacting front and rear upright.

47. Mount the centered pegboard

    Fasten the purchased perforated pegboard to the three mounting rails above the main bench.

    • Center the pegboard between the tall uprights.
    • Clamp its bottom edge 3" above the main worktop.
    • Drill the marked mounting holes between the factory perforations.
    • Drive 4 screws into each mounting rail.
    • Check a sample peg hook in an unobstructed part of the panel.

48. Fit the lighting overhang

    Attach the 2x6 overhang above the main bench as a future task-light mounting surface.

    • Rest the overhang on the two upright tops with a helper.
    • Align its rear edge flush with the upright backs.
    • Clamp the overhang level across the main workbench.
    • Drill pilot and clearance holes over both uprights.
    • Drive 2 screws down into each upright.

49. Finish and check the workstation

    Seal the exposed wood and verify the shelves and four sliding tote positions before loading.

    • Remove dust from the assembled workstation.
    • Apply polyurethane according to the product instructions.
    • Allow the finish to cure fully before use.
    • Check every screw connection for tightness.
    • Test the empty assembly for rocking and racking.
    • Test four empty totes together in each tower through their full travel.

50. Arrange the corner computer area

    Reserve the corner desktop for the computer beside the additional and inward-return workbenches.

    • Place the monitor on a stable stand at the rear of the corner desktop.
    • Position the keyboard and mouse within comfortable reach.
    • Reserve adjacent counter space for clean staging.
    • Route cables over the outer rear edges away from walking routes.
    • Check the equipment ventilation clearances against its instructions.