The 6'9" Workbench

Reference

Dimensions, the plinth-height formula, the cut list, the gotchas, the glossary, and what to measure before you buy. Print this page; it's the one you'll keep at the bench.

Things to measure or confirm before buying anything

Each of these can cost you money or a wasted weekend if you skip it. Tape measure, level, half an hour.

  1. A real cabinet's height. The catalog says 37 1/8", but assemble one and measure to the top of its wood top — it can vary 1/4–1/2". This number sets the plinth height (below).
  2. Cabinet stair clearance. Each cabinet shell is ~30" tall and ~46" long. Confirm a box that size makes it up your stairs and around the landing before you buy two of them.
  3. Top stair clearance. Carry a 98" cardboard tube or scrap from the driveway to the bedroom. If it doesn't make the corner, the top won't either — you'd need a two-piece top with a seam.
  4. Back-wall stud locations. Run a stud finder along the back wall now. Confirm at least 5 studs across the run for the ledger's lag bolts.
  5. Left wall plumb. Hold a 4-ft level vertically against the left wall. More than 1/4" out → plan a scribed filler strip or a thin caulked seam.
  6. Back baseboard depth. If it projects more than ~5/8", notch the back of the plinth or add a spacer so the cabinets sit plumb.
  7. Wall outlet location. Confirm the existing outlet lands behind the end column (or behind a cabinet you can route to) so the pop-up's cord reaches.
  8. Veneer top or solid butcher block? Decide now — it changes the top fastening (brackets vs figure-8s) and the cut-edge care.
Don't skip the haul check

People underestimate stairs. Two 186 lb steel cabinets and a 98" top all have to make the same turn. A box that won't pivot up the stairwell is a return trip and a redesign. Dry-run the dimensions with cardboard before you spend.

The plinth-height formula

Side-section diagram of the bench height stack from the floor up: a 9 3/8 inch black plinth, a 37 1/8 inch cabinet on casters, and a 1 1/2 inch wood top, totaling 48 inches. The top overhangs the cabinet front by about 6 inches.
Plinth + cabinet + top = counter height.
Counter target48"
− Top thickness1 1/2"
− Cabinet height (measured)37 1/8" (catalog)
= Plinth height9 3/8"

A 2x10 is 9 1/4" actual — shim ~1/8" to hit 9 3/8", or accept a 47 7/8" counter. Always dry-stack cabinet + top on the finished plinth and confirm 48" before fastening anything.

Final dimensions

Overall width~98" (two cabinets at 92 1/2" + ~6" end column)
Cabinet (each)37 1/8" H × 46 1/4" W × 18 1/4" D
Cabinet weight (each, empty)186.5 lb
Drawers9 per cabinet (18 total) — two 200 lb, seven 100 lb each
Plinth height~9 3/8"
Counter height48"
Top98" × 25 5/8" × 1 1/2"
Front overhang~6"
Approx. loaded weight~500 lb

Cut list — the wood base only

You buy the cabinets; you only cut the plinth, the end column, and the wall ledger. Size everything to your measured cabinets; these are the nominal numbers.

2x10 pine (1 1/2" × 9 1/4" actual) — plinth frame

PartQtyLength
Plinth long rail (front & back)292 1/2"
Plinth end cap215 1/4"
Internal joist~615 1/4" (every ~16")

3/4" plywood

PartQtyDimensions
Plinth top deck192 1/2" × 18 1/4"
Plinth skirt (front)192 1/2" × ~9 3/8"
Plinth skirt (exposed end)118 1/4" × ~9 3/8"
Retaining curb stripsas neededripped ~1" tall, around each cabinet base
End-column panels2–3~6" or 18 1/4" × 46 1/2"

2x4 pine

PartQtyLength
Wall ledger (anti-tip)1~92 1/2"
End-column frame uprights2–4~45"

Wall anchor detail

Top-down cross-section: a 2x4 ledger in front, drywall in the middle, wall stud behind, with a #14 by 4 inch lag bolt passing through all three layers.
The ledger lag-bolts to studs; the cabinets and top tie back to it. Six bolts minimum, each into a real stud.

Amateur gotchas

The shortlist of things first-timers miss with this design:

1

Measure a real cabinet before cutting the plinth. Catalog height can be off 1/4–1/2". Dry-stack and confirm 48" before committing the cut.

2

Never carry a loaded cabinet upstairs. 186.5 lb whole; ~100 lb as an empty shell. Strip the drawers, strap the shell to a hand truck, use a helper.

3

Anti-tip is not optional. Lean-into-it leverage at 48" with a 6" overhang wants to pitch the bench forward. Lag the ledger to studs and tie the assembly to it.

4

Capture the cabinets on the plinth. A curb/lip keeps ~190 lb cabinets from creeping off the front. Lock the swivel casters.

5

The IKEA top is veneer, not butcher block. Don't chop, don't wet the cut edges, seal the outlet hole. Upgrade to solid butcher block if you want a true work surface — and then use figure-8 fasteners.

6

Match the black. Factory powder-coat has a specific sheen. Test your paint on a scrap against a cabinet so the plinth and column don't read as a different black.

7

Prime the pine. Knots bleed orange-yellow through black paint for months without a stain-blocking primer.

8

Don't over-drive screws into the top's particleboard core. Pilot every hole; it strips easily.

9

Floor loading. ~500 lb in one upstairs spot. Level the plinth on carpet, let it settle, and re-level after a day.

Glossary

Plinth
A low base box the cabinets sit on, here ~9 3/8" tall, to raise the counter to standing height. Built from 2x10s and plywood, painted black.
Curb (retaining curb)
A shallow lip on top of the plinth deck that pens the cabinet bases in so they can't roll or slide off the platform.
Ledger
A horizontal board (here a 2x4) lag-bolted to the wall studs. The bench ties back to it so it can't tip forward.
Lag bolt
A thick wood screw with a hex bolt head. Anchors the ledger into wall studs. Driven with a socket or wrench, not a screwdriver.
Stud
A vertical 2x4 inside your drywall. Gives the lag bolts something solid to bite. Find them with a stud finder.
Caster
A wheel on the bottom of each cabinet. These are 5"×2"; two swivel and lock. Kept on and captured by the plinth curb.
Plumb
Perfectly vertical. A wall is "plumb" when a level held against it reads center. Houses settle; walls rarely are.
Level
Perfectly horizontal. The plinth is "level" when a bubble level on it reads center, both directions.
Square
Corners meet at exactly 90°. Test the plinth frame by measuring both diagonals; if they match, it's square.
Powder coat
The baked-on factory finish on the steel cabinets. Durable and a specific sheen — match your paint to it.
Figure-8 fastener
Two metal rings joined at the center, used to attach a solid wood top so it can expand and contract. Not needed for this veneer top, which barely moves — but required if you upgrade to solid butcher block.
T-nut
A metal insert with internal threads and outer prongs. Hammered into a hole; you thread a leveler or bolt into it. Used in the plinth corners.
Pilot hole
A pre-drilled hole that guides a screw or lag bolt. Smaller than the threads so they grip without splitting the wood.
Clearance hole
A pre-drilled hole the diameter of the bolt shank (no thread grip), so the bolt slides through one piece to pull it tight against another.
Scribe / scribed filler strip
A board cut to match an uneven wall so the bench's straight side meets the wavy wall with no gap.
Self-leveling enamel
A cabinet-grade paint that smooths out brush and roller marks as it dries.
End grain
The cross-section of a board where the growth rings show. Screws hold poorly in it; add glue.