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After trimming the top to size, chuck a ½" rabbeting bit in your portable router to cut the spline groove in each end of the worktop (see the exploded view on page 10 and Figure 1).

Rip a 3"-wide strip off one side of the top, and set it aside. Then, biscuit, glue, and clamp the inside liners (pieces 2) in place. Place the worktop on a couple of saw horses while attaching these liners, so your clamps have room to operate.

The liners need to be flush with the top of the butcher block when it’s finished, so it’s a good idea to set them in place a hair proud of the top rather than shy of it.

Getting Started

You should have the vise and bench dogs on hand before construction begins, in case you have to adjust the plan to fit the hardware. Beech and hard maple are the traditional species of choice for the frame and top, and walnut makes an excellent accent. During the course of construction, you’ll use a table saw, a biscuit joiner, a band saw, a drill press, portable and table-mounted routers, and a belt sander.

The bench dog holes are formed when a series of spacers (pieces 3 through 5) are attached to the liners. The business edges of these spacers are cut at a 2° angle (verify this angle by reading the bench dog manufacturer’s instructions), and they’re notched to allow the bench dogs to be stored below the worktop surface. All of these dimensions are shown in the elevation drawings, and the cuts can be made on a band saw. Dry fit and mark the spacer locations on the inside liners, verifying each placement with a bench dog (see Figure 2 on page 11). Score a shallow line about a ¼" in from the edge on both sides of each spacer—use a sharp knife or a rotary tool—to create a glue well; this will limit excessive squeeze-out.

Figure 3: Use your drill press to bore two-step slotted holes in the endcaps. These will allow the benchtop to adjust to various levels of moisture in the workshop.

Attach the spacers to the inside liners with glue and clamps. When they’re dry, you can glue and clamp the outside liners (pieces 6) in place. Use biscuits and glue to attach the remaining 3"-wide butcher-block strip to one of the outside liners (see the exploded view on page 10 for its location). Then, glue and clamp the worktop sides (pieces 7) in place.

Material List

		T x W x L
21	Toolbox Top and Bottom (2)	¾" x 15¾" x 35½"
22	Toolbox Sides (2)	¾" x 15¾" x 16"
23	Toolbox Divider (1)	¾" x 15" x 15"
24	Toolbox Back (1)	¾" x 16" x 36"
25	Toolbox Trim (1)	¼" x ¾" x 120"
26	Door (1)	¾" x 113/8" x 14¾"
27	Door Stiffeners (3)	½" x ¾" x 14¾"
28	Hinges (2)	European-Style
29	Toolbox Top Trimmers (2)	¾" x 1½" x 16¼"
30	Knobs (4)	Brass