Mobile bench — assembly guide

Horizontal top: 1800 × 900 mm · Overall length with panel: 1837 mm · Working height: 800 mm

Parts to prepare

Sizes below come from the model. Check actual stock thickness, joint fit and cutting allowances before cutting. Open the frame or exploded view to identify each part; click a component in the model to see its dimensions.

Timber allocation

Nominal cutting plan, checked against generated frame parts. Kerf and end trimming are planning allowances, not measured saw kerf. Leg pieces are finished lengths: rough-cut with trimming allowance before lamination and finish square after curing. Preserve the longer pieces first; do not cut a whole stock length into legs before allocating the rails. Allow rough leg trimming surplus from the remaining stock in each allocated length; finish sizes below apply after lamination. Never shorten the top to the superseded 1763 mm.

10 stock lengths of 2400 mm; allow 3 mm per cut and 10 mm for end trimming per stock length.

End-panel blanks

Cut one plywood backing and one MDF face, each 900 × 421 mm, at their respective sheet thicknesses. The horizontal sheets butt against the backing; the finished outer envelope including the panel is 1837 × 900 mm.

Top fixing schematic

Future MATCHFIT track centrelines only, not cuts: midway between the 96 mm dog-hole lines. Owner has accepted the 16 mm MDF for this use; tracks remain reserved for later routing. Black crosses show 24 proposed 4 × 30 mm MDF-to-plywood screws, offset a quarter pitch from dog centres and track lines. No glue. Keep saw paths clear of screws; these markings do not define a safe cutting lane.

Blue dashed: future track centrelines, not routed grooves. Black crosses: 24 top screws. Circles: dog holes.

All positions measured from the same top-left corner in this plan. Screw columns: 60, 348, 732, 1068, 1452, 1740 mm. Screw rows: 42, 330, 570, 858 mm. Place one screw at each column/row intersection.

Future track positions

Across the length: 132, 228, 324, 420, 516, 612, 708, 804, 900, 996, 1092, 1188, 1284, 1380, 1476, 1572, 1668 mm. Across the width: 114, 210, 306, 402, 498, 594, 690, 786 mm. Horizontal grooves meet the vertical panel at that end; use the opposite end for entry. Vertical panel grooves remain open above.

Removable end panel and tool holders

Owner accepted 16 mm MDF for MATCHFIT on 2026-10-01 in codex task 01a0c8f7-7301-75a3-9a9f-48422c7147f0. This is an owner design decision, not manufacturer certification. Add removable clamping panel at the end opposite the half shelf and removable tool holders beside the shelf. View proposal: panel height is four dog-grid pitches; plywood backing matches the structural top. Holster openings and mounting hardware need fitting to the actual tools; castor pedal sweep and attachment hardware need checking. Accessories are proposed geometry, not a final cutting schedule.

Owner correction 2026-10-06, task 01a0c8f7-7301-75a3-9a9f-48422c7147f0: retain both horizontal sheets at 1800 × 900 mm. Extend the doubled upper frame to the top edge at the panel end; four upper long rails are 1688 mm. Place the 21 mm plywood-backed 16 mm MDF vertical panel outside that edge, with its top flush: total length including panel is 1837 mm. End-panel blanks remain 900 × 421 mm. Legs and lower frame remain unchanged. Cleats run along the other three sides. Vertical grooves load from above; top grooves load from the opposite end unless a separate entry detail is designed. Panel bolts remain provisional and drilling is deferred until after the main table is built.

Corrected removal geometry, 2026-10-02, task 01a0c8f7-7301-75a3-9a9f-48422c7147f0. The former pads below the fixed cleat blocked lifting and are superseded. Holder backplates now stand outward by one plywood thickness, with upper packing behind the mating cleat and bearing pads against the FRONT face of the fixed cleat. Pads slide beside the rail, not beneath it. Remove retaining knobs completely, lift 31.5 mm (derived from 1.5 times nominal plywood thickness), then pull outward. This leaves 10.5 mm disengagement above the bevel and 4.5 mm clearance beneath the plywood top. Dimensions are nominal: confirm fit with actual stock. Three fixed 45-degree cleats remain directly on the 120 mm upper frame, excluding the vertical-panel end. Future wall rails must match this bearing arrangement as well as the bevel. Fixing sizes, loads and plywood allocation remain to detail. Outer dogs and clamp swing require checking with actual accessories.

Owner accepted plain crossbar with recessed panel screws and captive nuts on 2026-10-01, task 01a0c8f7-7301-75a3-9a9f-48422c7147f0. Supersedes MATCHFIT mounting tracks and entry notches. Counterbore/clearance sizes retained as plan-based visual placeholders pending chosen bolt heads, washers and nuts. Hardware glyphs are illustrative; select exact sizes and verify wrench access before drilling. Tray and holster use French cleats; wall installation remains future work. Owner sequencing decision 2026-10-06, task 01a0c8f7-7301-75a3-9a9f-48422c7147f0: build the main table first; resolve and fit the vertical panel attachment afterwards. Reserve its envelope but do not drill panel bolt holes yet.

Proposed end panel: 900 × 421 mm, with 16 mm MDF facing and 21 mm plywood backing. It sits opposite the half shelf. The MDF face fits the large top offcut. Backing and holder material allocation must be checked before cutting.

The model shows 2 open-front tool slots and a shallow tray on the long side beside the shelf. These are layout proposals: measure your tools before cutting the slots. The model shows the support brackets and removable hand-knob positions; exact fasteners remain to select.

Assembly order

Lower rail top edges: 180 mm above the floor. Dog holes: Ø20 mm on a 96 mm grid, through both sheets.

1. Check delivered material before cutting

   The frame requires ten 2400 mm lengths of nominal 60 × 40 mm stock. Measure actual stock and both top sheets; leg length is 800 mm minus their combined thickness (763 mm only for 21 + 16 mm sheets). Mark the BORA bracket locations and frame screw paths before laminating.

2. Allocate the long rails first and confirm actual top thickness

   With the recorded Makita DHS680, cut the eight separate leg pieces square to their finished length (800 mm minus the measured combined top thickness; nominally 763 mm), with the 40 mm stock thickness under the blade. Check all eight against one master piece. Dry-pair them, then glue broad faces together and clamp straight with both ends flush; recheck alignment after tightening and allow the glue to cure. This avoids trimming the laminated 60 × 80 mm legs, whose minimum depth exceeds the DHS680 single-pass capacity of 57 mm (Makita manual: https://www.makita.ca/data/upload/owners_manuals/DHS680%20-%20EN%20FR%20SP.pdf). Oversize blanks followed by trimming are an alternative when a suitable cutting setup is available, not a requirement. Keep any clamping screws clear of frame joints and castor mountings.

3. Build the doubled upper perimeter

   Dry-assemble both courses of long and end rails on a flat surface; top edges of the upper course and internal crossmembers are flush. Join the two courses into one assembly only after agreeing fastening positions clear of leg and panel bolts. Compare diagonals and keep the frame untwisted. Internal crossmembers remain one course deep.

4. Fit the legs inside the upper frame

   Their tops finish flush with the top of the frame, directly beneath the plywood. Match the leg orientation shown in the model so the lower rails fit between them. Clamp, check that the legs stand square to the frame, then fasten through the frame into the leg faces.

5. Fit the lower rails between the legs at the modelled shelf support level

   Dry-fit the long and end rails together, keeping their top edges level. Stagger the perpendicular screw paths through each leg so they do not collide. Check the frame for square and twist before tightening.

6. Fit the lower plywood shelf

   Cut its corner notches to clear the assembled legs, test the fit, then fasten it to the lower rails. Support the panel while fitting it and check that every edge intended to bear on a rail is supported.

7. Dry-fit the horizontal sheets and flush end panel

   Horizontal sheets end against the panel backing; the panel rises to the finished top surface. Retain the original overall-bench datum for the dog grid and screw coordinates, on the full-length 1800 × 900 mm sheets. Mark the frame below and omit blocked holes. Follow the UJK instructions, drill each sheet with backing and registered datums, and test actual dogs and clamps in an offcut first.

8. Fasten the top

   Secure the structural plywood to the upper frame, then screw the replaceable MDF to the plywood without gluing the layers together. Use the 24 positions in the top fixing schematic, clear of dog holes and reserved future track lines. Keep screw heads flush and out of planned cutting paths. Do not rout the future tracks during this build. Use fixings short enough to avoid projecting through the underside of the two-layer top.

9. Assemble the half-length shelf insert

   Stand its two side panels on the lower shelf, fit the back between them and fit the shelf on top. Dry-fit it in one end of the bench and check the intended tools fit above and below before cutting the insert panels to final height. Glue and fasten the insert as a separate unit; keep it removable from the main bench and leave the other half open.

10. Mount the retractable castors

    Use the selected kit’s mounting template and supplied instructions to set the brackets on the leg sides. Check screw lengths, edge distances and pedal clearance against the frame fixings before drilling. With the castors raised, the wooden feet must bear on the floor; with them lowered, all feet must clear it for moving.

11. Finish and check the bench

    Ease sharp edges, seal exposed sheet edges and apply the chosen finish without filling the dog holes. On the working floor, check for rocking, loose joints and racking, then check castor operation and the finished top height. Keep dogs and clamps clear whenever the top is used as an outfeed support.

12. Defer the vertical panel attachment

    Build the main table first, reserving the flush-panel envelope outside the full-length horizontal sheets. Owner will resolve panel fixings afterwards. Do not drill the illustrated panel bolt holes or counterbores yet; they remain placeholders. Trial-fit the panel later and keep its top flush with the horizontal MDF.

13. Support the vertical panel

    Extend the upper long rails only at the panel end, double the full upper perimeter and join its courses into one assembly. Attach the panel with two vertically separated bolt rows. Assemble tray and holster with plywood support brackets; fit matching French cleats and a retaining hand knob per module. Check fastener lengths, access and dog-hole paths before drilling. Hardware symbols are not drilling templates.

14. Fit three French-cleat rails directly to the doubled upper perimeter, leaving the vertical-panel end clear

    On each holder, use upper packing behind the mating cleat and pads bearing against the fixed cleat front face; do not put pads beneath the cleat. Fit removable retaining knobs. Remove knobs completely, lift the unloaded holder, then pull it outward. Check the full removal path with actual stock before final fastening.

Using the bench with other supports

Set the Wolfcraft and Stanley horses with saddles level with the bench for stock support. Check their loaded heights on the working floor.

Build the future table saw a separate mobile base sized around the selected machine. Set its table just above the bench so material feeds onto the bench along its long axis. Check runner clearance, fence travel, extraction and controls before building the saw base.