Building a sturdy, functional workbench for your garage or workshop is an essential DIY project that can provide you with years of reliable use. Rather than purchasing an expensive ready-made workbench, you can save money by repurposing old metal cabinets into a customized bench to suit your needs. With some basic tools and materials, you can create the ideal workbench from metal cabinets in no time.
Select the Right Metal Cabinets
When selecting metal cabinets to convert into your workbench, look for the following characteristics:
- Sturdy construction – Thicker gauge steel and reinforced corners will provide durability. Avoid thin, flimsy metal cabinets.
- Adjustable shelves – Shelves that can be removed or adjusted will allow you to customize the workbench height and storage.
- Sufficient size – Opt for longer cabinets around 30-50 inches to allow enough workspace. Standard width is ideal.
- Matching cabinets – Using 2-3 identical cabinets will create a uniform look.
Standard kitchen cabinets, lateral filing cabinets and garage tool chests are all great options to use. Make sure the cabinets are in good, straight condition before purchasing.
Prepare the Cabinets for Assembly
Once you have the metal cabinets, some prep work is required before joining them together:
- Remove doors/drawers – Eliminate anything that will get in the way during the build.
- Take out shelves – Shelves can be replaced later if needed. Removing them allows access inside.
- Clean surfaces – Use degreaser to remove any oil or dirt from the cabinets.
- Sand paint – Lightly sand any painted surfaces to rough them up for joining.
- Gather materials – Purchase lumber, hardware, tools for assembly ahead of time.
- Check for level – Before joining, verify cabinets sit level and stable on their own.
Proper preparation will make the rest of the project run smoothly.
Join the Cabinets Together
With the cabinets prepped, you’re ready to integrate them into a unified structure:
- Position cabinets – Place in the desired layout and verify they are level.
- Mark joining points – Note where you will attach braces/stretchers inside and out.
- Attach lumber – Use 2x4s cut to size to join inner sides of cabinets at marks.
- Add outer supports – Attach 2×4 stretchers to outer sides and back of cabinet assembly.
- Use construction adhesive – In addition to screws, adhesive creates a stronger bond.
- Install corner braces – Braces reinforce the front and rear corners.
- Check for square – Confirm the cabinets form a square shape when joined. Adjust if needed.
- Let dry – Allow adhesive and connections to fully cure before moving on.
Joining the cabinets into a solid rectangular unit is the most crucial step. Take your time here.
Add the Work Surface
The work surface is what transforms the metal cabinet assembly into a functional workbench:
- Choose work surface – Plywood, MDF board, butcher block are common options.
- Allow overhang – Size the work surface to overhang the front and sides about 1 inch.
- Cut support cleats – Rip 2x4s into 1″ thick cleats to support work surface.
- Attach cleats – Screw cleats into the inside top edges of the cabinet assembly.
- Install work surface – Set work surface on top and screw into cleats from underside.
- Seal/finish surface – Use polyurethane or oil-based finish to protect the work surface.
The overhanging work surface provides leverage for clamping and prevents items from slipping off the sides.
Add Storage, Lighting, Accessories
To complete your DIY metal cabinet workbench, consider adding:
- Shelving – Reinstall or add new shelves inside the cabinets for storage.
- Pegboard – Affix pegboard to the back for hanging tools.
- Electrical – Wire in outlets, lights, etc. as desired.
- Drawers – Install drawers for small parts, supplies.
- Vice – Mounting a vice provides an extra workholding option.
- Stool – A sturdy stool adjustable in height makes working comfortable.
Customize your bench with options tailored to how you work. Building it yourself allows this flexibility.
Maintaining and Protecting Your Workbench
Keep your custom metal cabinet workbench in top shape by:
- Using a protective pad – Help prevent dents and scratches on the surface.
- Keeping organized – Return tools to proper storage when not in use.
- Cleaning spills quickly – Use water and mild soap, dry thoroughly.
- Inspecting hardware – Tighten any loose screws, nuts, bolts.
- Touching up finishes – Reapply polyurethane or oil periodically.
- Avoiding moisture – Don’t allow water to sit on or soak into the workbench.
With proper care and maintenance, a metal cabinet workbench can serve dutifully for many years of projects. Building your own allows you to get the features you want at a reasonable cost. Keep safety and functionality in mind throughout the construction process. Before you know it, you’ll have a customized workbench perfect for your needs.
Frequently Asked Questions
What type of wood should be used to build the work surface?
Plywood, MDF board, and butcher block are common options. Plywood offers durability at a lower cost. Butcher block is attractive but requires more maintenance. Choose a material that fits your budget and project needs.
What is the ideal height for a workbench?
The best height is generally between 34-36 inches. This allows you to work comfortably without excessive bending or reaching. Customizing the bench using metal cabinets allows you to adjust it to your ideal working height.
Can other furniture be used instead of metal cabinets?
You can adapt other items like dressers, bookshelves, or storage racks into a workbench. The key is utilizing a stable rectangular structure. Metal cabinets make great building blocks for workbenches.
Should the work surface be flush or overhanging?
An overhanging work surface by about 1 inch is recommended. This allows you to clamp items that stay supported instead of slipping off the sides. It also provides leverage when sanding or planing on the bench top.
How much weight can a workbench made from metal cabinets support?
It depends on the cabinet construction, joinery, and work surface material. Typically several hundred pounds can be supported on a properly built metal cabinet workbench. Use additional supports for very heavy items.