How to Build Your Own Shop Table

In this one-day build we will create a custom sized shop table on wheeled casters for easy maneuverability and great functionality. This project only uses one sheet of hardwood plywood, two 4 x 4’s and a handful of 2 x 3’ lumber. Even with today’s record high lumber prices I purchased everything to do this project for under $150.
My motivation for this project was due to going to the store and finding similar shop tables priced at $500-$1000. By following the steps in this video you can also create an incredibly strong shop table and even customize it to fit your size needs.

I start by cutting down all my material to size starting with the sheet of plywood that serves both the top surface and the bottom wood shelf. I cut the 4 x 4’s down to length first and then proceed with creating a lap joint by cutting a 2 1/2 inch tall by 1 1/2 inch notch in the 4 x 4. This will accept the 2 x 3 and provide a very strong joint. Assembling the frame with a 3/4 inch overhang for the top table surface, I glued and screwed with hidden screws countersunk underneath the surface. I attach the 4 x 4 posts with structural headlock screws.

We created 45° brackets with another angle lap joint for strength and a beautiful final look. This can be created on the miter saw or by hand if you have the time. After countersinking a spot for our screw, we attach our bracket with three additional structural screws.

The bottom shelf is easy to build out of 2 x 3 supports and a piece of hardwood plywood that is cut to size. This is attached to the post using a similar Timber Lock structural screw. Installing the locking caster wheels to the bottom is a simple task with some pre-drilling and wood screws to attach everything securely.

To finish this workbench off I use 80 and then 220 grit sandpaper to sand every surface. I added a routed edge along the top surface to avoid any chips. To protect the surface against oil and water I put on two layers of a water-based polyurethane. Sanding in between each layer helps to remove any debris or bubbles that may form in the final finish.

Taking on a DIY project, renovation or a custom home build involves an incredible amount of decision making and planning. I aim to deliver value by showing how the process works. Learn from what is shown. Leave a comment with any questions for future topics.

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