Free workbench plans for a 5-foot garage workbench with a back panel and a lower shelf, cut entirely from two sheets of 18 mm plywood. You get the parts list, dimensions, material breakdown, and an optimized cutting diagram you can download as a PDF and take to the workshop.
The top is a single 1520×760 mm panel that sits on the side panels with a 30 mm overhang on each end so you have somewhere to clamp work. The work surface lands at about 878 mm (34.5") - the standard height for hand-tool and assembly work. Use cabinet-grade Baltic birch if you want the bench to outlive you, or sanded shop ply if you don't mind a project-quality finish.
Cut list for a workbench
The full cut list for this workbench is 13 parts across 8 part types: 1 top, 2 side panels, 1 back panel, 1 bottom shelf, 2 cross braces, front and back rails, and 4 shelf supports. Every dimension is in mm so you can move straight from cut list to saw fence without converting.
If you build your own cut list instead, the classic mistake is forgetting kerf - thirteen parts means dozens of cuts, and a dozen 3.2 mm bites add up to a shelf that no longer fits between the sides. The optimizer below applies kerf to every cut automatically and prints the exact sheet arrangement on a PDF.
What's in the PDF
- Parts list with dimensions - 13 parts total across 8 part types. Every part labeled, quantified, and dimensioned in mm.
- Optimized cutting diagram - generated from 18 mm plywood sheets (2440 × 1220 mm / 4'×8'). Color-coded by part type so you can see at a glance which piece is which.
- Sheet count and material cost estimate - this build packs into 2 sheets; the PDF shows the exact layout and cost.
- Kerf accounted for - 3.2 mm (1/8") default, adjustable to your blade.
Click "Open in Optimizer" below - your parts and stock are pre-filled, you just download the PDF. No signup needed for a single optimization.
Tools you'll need
- Circular saw with a straight-edge guide, track saw, or table saw - the 1520 mm top is the only awkward rip
- Drill driver and countersink bit - the whole bench goes together with glue and screws
- Pocket-hole jig if you want hidden fasteners on the rails, though exposed screws are honest on a shop bench
- Four clamps minimum for gluing the rails to the top
- Random-orbit sander - ease every edge you'll lean against
Time estimate
Half a day to break down both sheets and cut all 13 parts. Two to three hours to assemble. A first-time builder finishes in a weekend day with time left over; no finishing is required for a shop bench, though a coat of oil on the top makes glue drips easier to pop off.
Build sequence
1. Cut the top first. It's the largest part and the reference surface for everything else. One clean crosscut and one rip from the first sheet.
2. Cut both side panels at the same saw setup so they're identical - any height difference between them becomes a wobble.
3. Cut the back panel, shelf, rails, braces, and supports. The small parts (shelf supports, cross braces) come out of offcuts; follow the diagram and they all fit in sheet two.
4. Pre-drill the cross braces and shelf supports before assembly - it's much easier to glue and screw on the floor than once everything is upright.
5. Attach the shelf supports to the side panels, then join the sides with the back panel and rails. Square the assembly before the glue sets.
6. Drop in the bottom shelf onto its supports and screw it down. The shelf ties the base together and doubles the rigidity.
7. Set the top on last and screw it from underneath through the rails so no fastener heads show on the work surface.
8. Optional: drill bench-dog holes in a row 96 mm on center if you do hand-tool work. Skip them if the bench mostly serves as an outfeed or assembly table.
Sizing it to your shop
The 1520×760 mm footprint fits a single parking bay's side wall with room to walk past. If your space is tighter, shrink the top and the back panel width together and shorten the shelf, rails, and braces by the same amount - everything else is unchanged. If you want a mobile bench, buy 100 mm locking casters and subtract their height from the side panels so the work surface stays at 878 mm.
Material options
- Plywood (18 mm) - the default. Two sheets, screwed and glued, no hardware fancier than a deck screw.
- OSB - drops the material cost by roughly a third and holds the same loads in this design. Rougher surface; add a hardboard skin on the top if you care. Use the OSB cut calculator.
- MDF top over plywood base - dead-flat work surface for precision work. MDF sags under sustained load, so keep the plywood top and add MDF as a replaceable skin. The MDF calculator handles the numbers.
- Doubled top - laminate two 18 mm pieces for a 36 mm slab that takes pounding. Adds one sheet to the count; add a second Top part in the optimizer and it recalculates.
Common mistakes
Building it too high or too low. 34-36" suits most people for general work. Measure from the floor to the crease of your wrist - that's your bench height. Adjust the side panel dimension, not the top.
Skipping the back panel. It's what stops the bench racking when you plane or saw against it. A bench without one shuffles across the floor.
Assembling before pre-drilling. Plywood edges split when you drive screws near the ends without pilot holes, and inside corners are miserable to drill after assembly.
Using the factory edge as a reference. Sheet edges arrive dinged. Trim 10 mm off the factory edge before cutting parts, or set the trim option in the optimizer and it accounts for the loss.
FAQ
Are these workbench plans really free?
Yes. The plans, parts list, dimensions, and PDF cutting diagram are all free during early access. No card, no part limits, no watermarks.
What does the PDF include?
The optimized cutting diagram (sheet-by-sheet, color-coded by part), the full parts list with dimensions, kerf settings, and total sheet count. Designed to print at letter or A4 and be readable next to a saw.
How many sheets of plywood do I need?
2 sheets of 4'×8' (2440×1220 mm) 18 mm plywood. The optimizer packs all 13 parts into two sheets with kerf accounted for - the exact layout is in the PDF.
Can I make the bench longer than 5 feet?
Yes. Open the template in the optimizer and stretch the top, back panel, shelf, and rails together. Past 1800 mm, add a third side panel in the middle so the shelf and top don't sag.
How much weight can this workbench hold?
With 18 mm plywood, glue, and screws, the base carries far more than you can lift onto it - several hundred kg distributed. The practical limit is the shelf span; the four shelf supports and cross braces keep the 1484 mm shelf from sagging under toolboxes.
Should I add a vise?
The 30 mm top overhang on each end is sized for clamps and a front vise. Mount the vise before you fix the top down - you'll want access from below for the bolts.
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