So it has been a dream of mine for a couple of years now to build a hobby bench in my home office (a very modest 10.5' x 10.5' space) . This would be a multi-purpose bench where I can do some gun assembly, gun cleaning, reloading, and other misc stuff that isn't dirty enough to have to be done in the garage (like welding and woodworking lol). It's basically an indoor man bench!

So a few weeks ago I started planning and...well, I finally got to it! It didn't hurt that I needed a distraction from my wife's health problems (she's going in for surgery at MD Anderson on Wednesday...T&P please).

I'll break this out into a few posts - with lots of pictures! Of course the story isn't yet complete - still a lot to do: some sort of over bench storage/shelving, up top lighting, some more reloading stuff still, first loaded rounds, etc. But it's to the point now I feel like sharing.

To end this introduction...I just ask to keep the negative comments to yourself about the cost of this project. I've seen plenty of people on this forum and elsewhere complain about how people spend their money and, well, its mine to spend as I please! Yes, I could have done everything much cheaper - but that's not the way I roll. Just check out the DIY stuff and enjoy.

Oh - and why the title? I pondered a few options in my mind until I finally just now came up with "BeST bench"! As in...Blood (only a little thankfully!), Sweat, and Tears bench. I'm sure it'll get plenty more of all three in the years to come. It's also probably the best bench I've built so far (other 2 are a woodworking bench and a welding bench...I'm big into DIY if you couldn't tell).

OK, first up - design. Coming from a software developer background I like to design everything up front as much as possible. All the more important when what you are building is with metal and wood and costs hard money. I'm sure we've all heard the saying "measure twice, cut once"? Well there is an extension to that saying that goes something like this: "design three times, measure twice, cut once".

So that's what I did and eventually I ended up with something that would look like this (all done with the free version of SketchUp):






The biggest constraints on design were:

1) Will it fit? The main length of the bench is 7.5' - a few inches short of the door that will be close to the end of it when open.
2) Will it fit through the door/hallway (I didn't want to be "that guy" lol)? No way it would fit as one piece so I had to build it in two pieces and bolt it together in the room.
3) I wanted it to look "clean"
4) I wanted the top surface level with my existing desk height so that I can (eventually) have a full wrap-a-round surface. I like doing everything seated unless I'm in the garage.
5) I wanted shelf height/spacing to accommodate those plastic ammo containers from HF if I eventually decided to use them (I have a lot of them!). I've somewhat changed my mind on that now but no regrets.

Next up: Heavy metal!

Almost all parts of the frame are 11ga 1.5 x 1.5 tubing. The long front crossmember and the middle front to back support for it are 14ga for the extra support since there is no middle leg there (for knee clearance).

First up to build were the legs - after cutting them all to length I had to weld on something to screw the adjustable feet into. I used some long 3/8-16 weld on nuts and some (I think) 1/8" plate to weld them onto then welded all that to one end of each leg:




FYI, I used a Makita cold cut saw to cut all the parts. Much better than the slow-as-f*** HF bandsaw I used to use.




After that I built up the 5 leg pairs with their front-to-back supports in them. I then assembled everything upside down on my welding table. The reason I assembled it upside down is because I wanted the top to be the flattest (since the feet are adjustable). Lastly, to meet my design needs and to make fab as quick as possible I used some pre-made weld-on tabs with holes drilled in them to support the shelves and bolt down the top. The top is only lightly bolted down in the back to resist cracking due to expansion.












For finishing I just used some satin black Krylon - the one with supposed built in primer. I've sprayed just plain Krylon on metal before without primer and it's held up fine so I'm sure this will be as well. Just be sure you thoroughly degrease everything...twice. I used acetone.





Next up: The wood! (my wife's favorite part lol).

I'm in - equal parts jealousy and moral support.

So I built everything with pre-made (but unfinished) beech butcher block tops from Floor and Decor. They've got pretty good prices (compared to say shipping some Maple butcher blocks from Grizzly) and in the sizes I needed. And the quality is pretty dang good - I previously had used one for a gaming table I made so I knew what I was getting into.

Most everything I needed to cut was done with my Festool track saw (which I actually didn't buy - it was a gift from my mom years ago lol. Thanks mom!) or my DeWalt sliding compound saw. This made breaking down the large pieces pretty easy and only having to flip the larger pieces when finishing. Makes working mostly solo a piece of cake compared to having to haul plywood or MDF on top of a table saw (do not recommend lol).




Sometimes I got lazy and made full depth cuts with the track saw, but most of the time I did them in 2 passes. Beech is hard! When taking a full pass you'll get some inevitable burn marks. Where visible I sanded them out, where not I just left them there. Ain't no way I was gonna waste my time sanding something nobody would ever see. Keep in mind this isn't a new blade...




Hardest part was routing out the cutouts to recess the Inline Fabrication quick change plates. Thankfully I didn't screw anything up and didn't have to redo either of the two top pieces! I just clamped some wood in place to make a template then used a guide bushing in my router. Went slow and took multiple passes then drilled the mounting holes.










For a finish, I used Arm-R-Seal from General Finishes. First two coats I rubbed on with a cotton cloth, final coat I used a foam brush. The foam brush leaves a thicker coat than the cloth and I didn't want the thickness I would have ended up with if I had used it for all three coats. Since its an oil based finish this meant 1 coat a day, 3 days total. Yawn...


Next up: Getting it assembled!

Just logged in to say that is bad ass, keep it going!

That's awesome. I'm really digging that welding table too.

Probably the easiest part of the whole build. The two main metal pieces were actually not all that heavy - an easy 2 person job to walk them into the house. The main top was heaviest, but it went in without a hitch as well as all the other parts. It all goes back to designing and measuring everything up front! As previously mentioned the top is lightly screwed down in the back to help resist cracking under expansion/contraction. All through holes (for the quick mount plates, etc) are slightly oversized as well.












Next up was power - I got 2 power strips ( https://www.amazon.com/dp/B007ZT2XT0 ) to mount upside down underneath the top. I had also already cut a square out of the back corner of the top to drop cables through. The back edges extend past the frame by 1.5" to allow for cables to be dropped down, etc.

Second up was getting some light underneath there. I found a couple of cool LED lights with magnetic backs on Amazon ( https://www.amazon.com/dp/B08ZKCD4YT ) that I have just slapped on some metal underneath the top. You can leave them plugged in but they have a bonus of having a battery so you can pull them off and use as a portable light if you need to (or to easily remove them if it turns out they affect my powder scale!). Bonus is that they have a motion sensor to automatically turn them on when you're trying to get into something down there.




Late addition to the design were some under-top hangers I could use to sit long stuff like cleaning rods - far enough back and high enough not to bump knees against! Not sure if this will turn out to be a good idea or not. Worried about 1) the rods bending over time, and 2) blocking storage. We'll see.




Next up: Organization and reloading gear!

dr_boogs said:

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I'm in - equal parts jealousy and moral support.

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This is the way.

Looks awesome OP

While the bench itself will be used for multiple purposes, the storage around it will primarily be dedicated to reloading. Other than that, I have a nice size closet in the room with floor to ceiling wire shelves to hold other stuff (like the Hodgdon 8lb containers that I didn't realize are too tall for my new bench shelves by like .5"...grrrrrr!).

I had originally wanted to use some of those HF ammo boxes ( https://www.harborfreight.com/030-caliber-ammo-box-63135.html ) since I have like probably 30 of them. Unfortunately (fortunately?) most of them are filled with ammo sitting on the bottom of my closet!

Looking around I've decided on some Akro-bins (eventually with covers) and some other large containers I found on Uline that will fit the shelf spaces nicely. I only have some of the Akro-bins so far.

Moving past storage - we have the reloading gear. I've been assembling stuff for a few years now so not all of this is brand spanking new. Maybe I went over the top a bit lol? But I don't care - my plan was to reload for precision and ease, not mass shooting. Buy once, cry once and all that bs. I'll skip the mansplaining of it all. If you reload, you probably know what it all does, and if you don't (yet) - well, you probably shouldn't be looking at these next pics!

Oh wait, I forgot to mention the one little thing on the corner of the bench: an Orange bench vise. Biggest selling point for me about this vise were the jaws and barrel vise bushings available from Area 419 that allow you to clamp anything with an Arca mount or picatinny rail onto it easily as well as grip most barrels for assembly. Anybody want to buy my used but good condition PMA barrel vise?

Having said all that, here are the pics as of now - pending some more organization and the earlier mentioned stuff like some lighting up top and what not:








I wasn't 100% happy with the Inline Precision quick mount system. It was designed to overhang a bench by 1.5" but to me that is just a horrible idea - I wanted it flush with the front of the bench. I understand why they did it - but for the equipment I planned on using it wasn't needed. So I drilled out their quick plate 1/4-20 studs they had and instead opted to use a full length 1/4-20 bolt that goes through the top and frame of the bench and tightens down with a knob from the bottom. Only other thing I had to do was drill a couple holes through the Henderson base plate so that I could drop the bolts through. The other plates for the Zero and Primal Rights don't overlap those hole locations so I didn't need to modify those.






Storage for quick plate mounted gear, one on each end:




Feel free to star all my posts in an effort to BTHO cancer (or just because you think DIY stuff is cool as f***)! It took three hours of (thankfully) not thinking about it to write this all up! Now I'm just gonna go cry in a corner of the hospital for a few days and hope it all works out. I've literally put every spare moment I had these last few weeks working on this to get my mind off of it.

Gig'em!

Excellent, my man. Impressive work.

Just one possible issue: How will you sit at that desk?

Sazerac said:

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Just one possible issue: How will you sit at that desk?

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Combination of my office chair and a height adjustable drum stool on wheels (I used to have a Roc-N-Soc when I used to play...need to get a new one). Something like this but with wheels (you can get a back support for them as well):



I designed the storage under the main bench area to be far enough back to not hit my knees. And there is plenty of room for feet under the bottom shelf.

Edit to add: top height is 30.5" - same as my desk. My woodworking bench is 36" and welding bench is 40". Different heights for different tasks. I get that some people like to reload standing up - but that's not for me. I like my butt in a seat. And given that this is a multipurpose bench it was the best option.

Said a prayer for your wife as I'm sure many, many others have.

I'm sorry your wife is dealing with cancer. I lost my Dad late last year to it, and it sucks in all forms and varieties. I hope she pulls through it.

Oh yeah, and great job on the bench.

Looks awesome! Prayers for your wife. You too.

Great job sir! Also will be praying for your wife as well.

Wow! That's one of the best project builds I have ever seen on the OB. Yes, I'm jealous.

Prayers for you and your wife!

I think that qualifies as heavy duty...awesome stuff sir

Great Job!!! Prayers for your wife.

I'm highly impressed, not only by your bench build, but also your reloading equipment... damn!

 

Outstanding job! Also, prayers up for your wife.

Great job, and BTHO cancer!

Well done, sir.

I wanted to post some smart ass remark about spray paint instead of powder coat...but it is so badass I could not do it! Awesome job! Prayers to your wife.

Did you make a jig and clamp it to table to route in for the in-line fab mounts? About to do this and I'm not the most skilled at routing.

Looks awesome, hopefully mine turns out 1/2 as good.

Great job on the bench! Prayers for your wife. We serve an amazing and loving God

John Cocktolstoy said:

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I wanted to post some smart ass remark about spray paint instead of powder coat...but it is so badass I could not do it! Awesome job! Prayers to your wife.

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Funny you mention it. I was in Home Depot one day a couple of weeks ago and the people in front of me had on t-shirts for their powder coating company! I chatted with them and got their number but eventually just decided to paint it myself. Reason being that I figured if I wanted to change something later it would be easier to touch up.

Very impressive!

BCOBQ98 said:

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Did you make a jig and clamp it to table to route in for the in-line fab mounts? About to do this and I'm not the most skilled at routing.

Looks awesome, hopefully mine turns out 1/2 as good.

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Sort of - I just clamped down some straight boards and set them out about 1/16" wider on each side to account for the guide bushing offset. You have to support all sides - even the exposed side on the front otherwise your router will drop through.

I had to do this twice for each one. The first time for the inner recess, then again for the outer (not so deep) recess.

Note that I highly suggest you get/make a larger base for your router since the size of the opening is larger than most router bases can handle. I didn't do that and instead did it the brute force hard way by putting a spacer in the middle to support the router then routed that part out separately with the boards reset.

Cool little LED magnetic machine light came in today from Amazon. Nice and bright!

And yeah...I'm a lefty.


Guess that's it for awhile. Gotta pack and drive into Houston.

Java.... first, we will pray for healing for your bride. If you feel comfortable just giving us her first name I will add her to our prayer list at our church. Then the prayers will grow.

The bench is just damn nice and awesome. Shows lots of Aggie pride sir.

Very nice! That's a bench that will last 100 years.

Gunny456 said:

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Java.... first, we will pray for healing for your bride. If you feel comfortable just giving us her first name I will add her to our prayer list at our church. Then the prayers will grow.

The bench is just damn nice and awesome. Shows lots of Aggie pride sir.

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Much appreciated. Her name is Gina (pronounced Jenna).

And thank you everyone for the kind words. You guys are the greatest!