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Workshop Organization Tips

5 projects for a better shop—adjustable sawhorses, a super-handy tool rack, a workbench with storage space, a miter saw stand and a silencer for your shop vacuum. They're all low cost, can be built in a day and are essential for the small shop.

By the DIY experts of The Family Handyman Magazine

Project 1: Adjustable height sawhorses

Every shop needs horsepower. These adjustable horses are easy to build from construction-grade 1x4s and 2x4s. Add the adjustable-height jig and these horses will hold projects at the perfect working height. Use a pair of them as a stand for portable or bench-top power tools, or make a temporary workbench by throwing a piece of plywood on top.

Sawhorse details

Sawhorse details

Figure A: Sawhorse Assembly Diagram
All parts are labeled and they key to a Cutting List you'll find in the Additional Information below. Note: You can enlarge Figure A by downloading it from the Additional Information below.

Project 2: Shop vacuum muffler box

Avoiding clouds of sawdust is a must in a small shop, but a dust collector eats up valuable space and money. A shop vacuum makes a good substitute, but because the decibel level of most shop vacuums rivals that of a jet engine, build this box to muffle the noise. Put casters on it and it'll follow along as you connect it to various power tools.

Build the box from a 4 x 8-ft. sheet of 3/4-in. plywood or MDF (medium-density fiberboard). Glue in wood battens at vertical corners for additional strength. Fasten with 2-in. screws. We lined ours with carpet scraps for extra muffling. Cut them to size and glue them to the box with construction adhesive. Use strap hinges on the door so the screws drive through the face of the door and box side. Avoid butt hinges because there's little holding power for screws driven into the edge of plywood or MDF.

Vacuum box details

Vacuum box details

Figure B: Shop Vacuum Muffler
Build the box from MDF or particleboard. Double-check the size of your vacuum to make sure it fits. You'll find the complete Materials List with hardware and a Cutting List in the Additional Information below. Note: You can enlarge Figure B by downloading it from the Additional Information below.

Project 3: Flip-through tool rack

Unless you live in an art gallery, wall space is always at a premium. Build this booklike storage rack, and expand your wall space exponentially. Grabbing a tool is as easy as flipping through a magazine.

Mount two parallel 2x4s on the wall spaced 24 in. apart. Cut the leaves from 3/4-in. plywood and hang them from the 2x4s with 3-in. door hinges. Fur out the hinges with 3/4-in. plywood blocks so the pages can pivot without binding. Mount the leaves at least 4 in. apart to allow room for them to fold back. Let your imagination run wild creating holders for your various tools.

Peg-board details

Peg-board details

Figure C: Peg-Board Leaf Option
For you Peg-Board fans, sandwich a 1x3 frame between two pieces of Peg-Board. Now your collection of hooks and holders will work with this tool storage system. Note: You can enlarge Figure C by downloading it from the Additional Information below.

Project 4: Workbench with built-in storage

At the heart of every small shop is a multipurpose workbench. Build this workbench with tons of storage space underneath. While ours is configured for lumber storage, you can put cabinet doors on the front and store tools and materials. For our 8-ft. long bench, we built four 2x4 frames; that left about 27 in. between them. This spacing provides plenty of support for the double 3/4-in. plywood top and long lengths of lumber underneath.

Workbench frame

Workbench frame

Figure D: Workbench Support Frame
These simple frames support the workbench. Simply connect them with the plywood fronts and tops to make the bench stiff and strong. Note: You can enlarge Figure D by downloading it from the Additional Information below.

Project 5: Full-feature miter saw stand

If dedicating 8 ft. of wall space to your miter box is just another fantasy, build this portable stand for your miter saw that provides all the features of a permanent miter saw table. When it's not in use, lean it against the wall or hang it from the ceiling. While you can build this from an 8-ft. 2x12, it'll be challenging to find a straight one. A good alternative is to glue together two layers of 3/4-in. AC plywood. Cut a 3/4-in. wide by 1/2-in. deep groove for the T-track with a dado blade on a table saw or with several passes with a router. Build the sliding supports out of 3/4-in. pine or plywood.

Miter stand

Miter stand

Figure E: Miter Saw Stand
The adjustable elements make this stand highly versatile. Note: You can enlarge figure E by downloading it from the Additional Information below. You can also download a Shopping List for the special hardware.
Caution!

Screw or clamp your stand to the sawhorses to prevent tipping.

Back to Top

Required Tools for this Project

Have the necessary tools for this DIY project lined up before you start—you’ll save time and frustration.

    • Circular saw
    • 4-in-1 screwdriver
    • Drill/driver, cordless
    • Drill bit set
    • Speed square
    • Table saw

Spade bit, 1/2-in.

Comments from DIY Community Members

Share what's on your mind and see what other DIYers are thinking about.

1 - 9 of 9 comments
Show per page: 20   All

July 23, 9:27 AM [GMT -5]

To those worried about the Adjustable Sawhorse tipping when putting pressure to one side the solution seems simple. Instead of leaving the locking pin to simply sit on the support timbers why not drill a hole for the pins through the support timbers?
That way the sawhorse is still just as adjustable and just as easy to use but it no longer has any opportunity to tip. No need for clamps or doing any other tricks, just two holes through the boards enough so the pin is a snug fit.
I would make it vertically centre between the pieces so that there is plenty of timber around the holes.

June 01, 6:06 PM [GMT -5]

Great Idea!

June 01, 5:59 PM [GMT -5]

How about drilling a hole through the top horizontal pieces, instead of resting the dowels on top.

June 01, 5:59 PM [GMT -5]

How about drilling a hole through the top horizontal pieces, instead of resting the dowels on top.

March 20, 4:09 PM [GMT -5]

This adjustable saw horse works fine with the exception of one bad design flaw. when you have it pinned to the height that you want it work and you happen to put pressure on one side or the other, not in the middle, it lifts the other side up. This is very annoying and makes this a less then good design. I use a clamp to prevent this from happening. Very much a pain.

May 21, 6:12 AM [GMT -5]

This project was a joy to do. The finished product is awesome! This sawhorse is so practical for all of my DIY projects and is so versatile. Now I can adjust my sawhorse to whatever height I need it to be, whether it be to use as an outfeed jig for my table saw for long cuts or just as a workbench. Great job on the design of this project! The Lord is good.

November 16, 8:24 AM [GMT -5]

great job on the problem of storage in a small shop

November 16, 8:22 AM [GMT -5]

To make the top of the sawhorse more stable I extended the bottom bar out far enough to sandwich both of the leggs.
It now also slides up and down better and is supported so the top stays stable.

November 16, 8:22 AM [GMT -5]

To make the top of the sawhorse more stable I extended the bottom bar out far enough to sandwich both of the leggs.
It now also slides up and down better and is supported so the top stays stable.

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