How To Build A Tool Bench

Enter This Old House general contractor Tom Silva, with a plan for a size-it-to-your-space tool-storage bench that doubles as a work surface. Though it may look complicated, the construction couldn’t be simpler: Tom used plywood to build one large box and two smaller ones, fitted them with shelves, then placed them back-to-back and topped the assembly with doubled-up plywood. See how he and Amy built it using just a few basic tools and materials.

Overview for Building a Tool Bench

Cut List • ¾-inch plywood top: two @ 38 by 72 inches • ⅝-inch plywood sides of boxes: nine @ 16 inches by 27¾ • ½-inch plywood back of large boxes: one @ 27¾ by 67 inches • ⅝-inch plywood bottom of large box: one @ 16 by 67 inches • ½-inch plywood back of small boxes: two @ 17 ¼ by 27¾ inches • ⅝-inch plywood bottom of small boxes: two @ 16 by 17¼ inches • ½-inch plywood shelves: six @ 16 by 16½ inches (if using cleats, cut shelves to 16 inches by 16 inches) • 1x2 horizontal filler strips: four @ 33 inches • 1x2 vertical filler strips: four @ 22 inches • 1x2 plywood rails: four @ 67 inches

Cut Box Parts

Using our online cut list and a circular saw guided by a straightedge, cut plywood backs, walls, bottoms, and shelves to size for one large and two small boxes. Use a router to make ½-inch slots on the inner walls where shelves will slide in. Pro advice: “If you don’t have a router to make slots for shelves, you can screw 1x2 cleats to the inner walls of the boxes instead, and affix the shelves to them.” —Tom Silva, TOH General Contractor

Build Boxes

Glue and screw the bottom pieces to the outer walls of the small boxes. Space the screws about 3 to 4 inches apart. Glue and screw the outer and inner walls, spaced at 16¾-inch intervals, along the bottom of the large box.

Install Rail for Large Box

Cut a 1x2 or scrap plywood to the large box’s length. After making sure the walls are square, screw the rail across the front to stabilize the box, flush with the tops of the walls. Cut an identical rail to install later across the front of the small boxes.

Attach Backs of Boxes

Apply glue to the exposed back edges of the boxes’ walls and bottoms. Set the backs in place, and fasten with screws spaced about 3 to 4 inches apart.

Assemble Base

Place the boxes bottom up and back-to-back, with the small boxes flush with the ends of the large box. Screw on cleats of scrap plywood laid across where the bottoms meet, using 4 screws on each box bottom. Drive 6 to 8 more screws through the backs.

Add Casters

Set casters at each of the base’s four corners, about 1½ inches from each edge. Set two more casters in line with the left and right inner walls near the back of the large box, about 1½ inches from the back edge. Secure with carriage bolts through the holes in the mounting plates.

Install Shelves and Second Rail

Flip the bench right-side up. Slide shelves into the slots cut in Step 1. (If a shelf is too tight, sand its edges until it fits.) Install the rail cut in Step 3 across the front of the small boxes and open base, flush with the tops of the walls.

Install Furring Strips and Pegboard

Flip the bench right-side up. Slide shelves into the slots cut in Step 1. (If a shelf is too tight, sand its edges until it fits.) Install the rail cut in Step 3 across the front of the small boxes and open base, flush with the tops of the walls.

Mount Power Strip

Measure the distance between the mounting holes on the back of the power strip. Mark their locations on the side of the bench, above the pegboard. Install the screws and mount the power strip to the side of the bench.

Add Top

Drill angled pilot holes through the tops of the bench’s sides, spacing the holes about 3 inches from the front and back. Screw together two sheets of ¾-inch plywood; cut to size. Center the top on the bench. Attach with screws driven into the top’s underside through the holes.