I love getting a great deal. Who doesn’t?  Workbenches can be so expensive, if you haven’t noticed.

Tools used (links are to Amazon.com):

• Stanley Tools Folding Sawhorse
• Hammer
• Chisel
• Hand Saw
• Drill with bits and phillips driver

So one day last week, I was on a quest to make a workbench for under $100.  This is what I came up with.  While surifing the web, I saw a post over at IkeaFans about someone who had to return their countertop because it was damaged.  Which got me to thinking: “Does my Ikea have a return section?”  And the answer is YES!

Since I’m lucky and only live 15 minues away from the Round Rock Ikea, I jumped in my car and boogied on over.  It was a Tuesday afternoon, and the place was empty (tip visit just after lunch on a weekday to avoid the masses).

I found the damaged/returns section and saw this beauty:

Check the returns area of Ikea (near the checkout) for some great deals

I was looking for a lighter maple wood color, but for $50 this would work!  The 8-foot long by 2 – foot wide box just barely fit in my Civic with the front passenger seat down.  On the way home I stopped at Home Depot and picked up a couple of 2×6′s, 2×4′s and some 3 1/2 Lag bolts to anchor everything to studs.

Notice the right side isn't anchored - I searched for a stud, but the closest one was 5" off the end. These tiny holes will be covered by the countertop.

After an hour of measuring cutting, chiseling, and screwing, I had the foundation in place.  I’m pretty tall at 6′ 1″ and like a 36 inch working height.  My Sawhorses are 34 1/2 heigh, and with the 1.5 inch countertop I had perfection.

Here’s a tip for determining your workbench height –  Stand against a wall with your palms facing down – you want a right angle (90°) at your wrist.  Mark the wall with the bottom of your palm, and that’s a good starting point.

I wanted to build the base of the workbench to be strong enough to float, but sadly the studs were on 24" centers.

The back 2×6 is mounted into studs in the wall, and notches are cut out for the 2×4 supports.  The front 2×4 is notched for the supports as well.

Tomorrow, I’ll post some shots of the top in place, and the next steps.