How to Build a DIY Mobile Assembly / Outfeed Table with pocket hole joinery

In this video I take you through how I built my mobile assembly table with lots of drawers to store tools and accessories that I use on a day to day basis. It's all made out of lumber you can find in your local big box store or local lumber yard.
Frame built out of 2x4 and 4x4 lumber
Drawer boxes, drawer fronts, drawer partitions made of 3/4" plywood
Top consists of 3/4" plywood covered by 1/4" hardboard and surrounded by 1x2 maple
Casters from Lee Valley
Drawer handles and drawer slides from Lowes
Some of the tools that helped make the job go smoothly included:
Kreg Tools ((www.kregtool.com)
- Pocket Hole Jig
- Right Angle Clamp
- Drawer Slide Jig
- Cabinet Hardware jig
TSO Products (tsoproducts.com)
- GRS-16 Guide Rail Square (tsoproducts.com)
- TPG Parallel Guide System
Festool Tools (www.festoolusa.com)
- TS 55 Track Saw
- Guide rail

[@DIYwithDennis]

Hi Folks, thanks for watching and let me know what you think of the video in the comments. below. If you liked what you saw, consider giving a 'thumbs up' and subscribing to the channel - Thanks! Dennis

[@bdm1000]

Beautiful. Matching the grain is a level of detail I hadn't seen before. Great job!

[@DIYwithDennis]

Thanks! Much appreciated! I picked that up from some other video's (don't recall which now) and thought it was a nice touch visually.

[@jettech1041]

Just what I need for my garage! Great work.👏

[@DIYwithDennis]

Thanks! Good luck with your build! Dennis

[@bigbawls81]

Great job not only with the directions and assembly but with the video editing as well. Thank you for sharing.

[@DIYwithDennis]

Thank You! Much Appreciated! Thanks for watching!

[@markkoons7488]

Seems like tempered Masonite hardboard used to be darker. I understand that darkness was the result of higher concentrations of linseed oil which was then baked in under pressure. Point is that the darker stuff resists the adhesion of glue better, a characteristic that can be renewed by polishing with a somewhat-linseed-oily rag. It's really nice to have dried glue pop off when you scale it.

[@DIYwithDennis]

Thanks for the tip! The few times that I did get glue on the top, it wasn't easy to get off without chewing up the top. I will give it a try! thanks again!

[@jaykepley5238]

Nice job!

[@DIYwithDennis]

Thanks Jay! Much appreciated!

[@NWGR]

Nice job dude! I'm sure by now you're loving having all that space to work on. For a finish I'm a huge fan of water based poly. Easy to apply, dries fast, no obnoxious smell, and it's plenty durable. Subscribed. Looking forward to seeing where your woodworking journey takes you. :-)

[@DIYwithDennis]

Thanks NW! Much appreciated! Yes, it's great to finally have a nice big assembly table with plenty of storage. Wish I had built it years ago .... and yes, you reminded me that I really do need to put a finish on it .... I will check out the water based poly you suggest - thanks!

[@DanMarantz]

Nice job Dennis. Let me know when you’re coming over to build one for me 😀

[@DIYwithDennis]

LOL!! Thanks Dan!!

[@kevenhavelette3723]

Nice build. At 3.28 we can see that the plywood isn't flush with the 2x4 used to make the frame. Later we can see that the offsite is actually perfect with the face of the drawers. My question is, what is the off-set you had between the 4x4 (feet) and the 2x4 ? Thanks

[@DIYwithDennis]

Hi Keven, had to run out and measure :) the 2x4's are set back 3/8" from the legs - let me know if you need more info - thanks for watching - Dennis

[@kevenhavelette3723]

@@DIYwithDennis thank you so much. I really appreciate.

[@michaelparker6081]

Hi Dennis, exactly what I've been look for for hours in Google. Drawers on both sides, mobile assembly table (will be used for new CNC I just got). Wondering if you have cut sheet or list of materials so I know how much to buy at local box store. Thanks again for the video, Mike

[@DIYwithDennis]

Hi Michael, I don't have a cut list or plan but I can get you some rough measurements to give you a good idea of the type and quantity of lumber to buy. Also, check out this video kzbin.info/www/bejne/epnXZ6WnbLSfr6s it's what I built to house my CNC I'll get back to you tomorrow, Friday, or Saturday at the latest. Dennis

[@michaelparker6081]

@@DIYwithDennis Thank you sir!

[@DIYwithDennis]

Hi Mike, Here are some VERY ROUGH measurements for the assembly table. They're not meant to be a cut list but they will give you a good idea of how much wood to purchase and then add your own touches to make it your own. Thanks for reaching out and Good luck with your project!! TOP - 94" long by 42" wide - 3/4" plywood - 1/4" hardwood - 3/4" banding added to the above measurements LEGS 4 - 4x4 x~29" (Douglas fir) RAILS 4 - 2x4x~69" (top and bottom long rails) 4 - 2x4x~27" (top and bottom short rails) BRACES for bottom shelf and top 6 - 2x4x~30" (3 on top and 3 on bottom) BOTTOM (below the drawers) 3/4 Ply - ~30" x ~ 72" END PANELS and DIVIDERS between banks of drawers 3/4" Ply ~21" high x ~ 30" high DRAWER BANKS SIDE 1 Bank 1 - 3 drawers - 3/4" PLY for drawer box and front / 1/4 Ply for drawer bottom - Drawer boxes are ~16" deep x ~16-3/4" wide and ~5-1/2" high - Drawer front is ~7" high x ~19" wide Bank 2 - 3 drawers - 3/4" PLY for drawer box and front / 1/4 Ply for drawer bottom - Drawer boxes are ~16" deep x ~17" wide and ~5-1/2" high - Drawer front is ~7" high x ~19-1/4" wide Bank 3 - 2 drawers - 3/4" PLY for drawer box and front / 1/4 Ply for drawer bottom - Drawer boxes are ~16" deep x ~27-1/2" wide and ~9" high - Drawer front is ~10-1/2" high x ~29-1/2" wide DRAWER BANKS SIDE 2 Bank 1 - 3 drawers - 3/4" PLY for drawer box and front / 1/4 Ply for drawer bottom - Drawer boxes are ~14" deep x ~16-3/4" wide and ~6" high - Drawer front is ~7" high x ~19" wide Bank 2 - 2 drawers - 3/4" PLY for drawer box and front / 1/4 Ply for drawer bottom - Drawer boxes are ~13" deep x ~17" wide and ~8" high - Drawer front is ~10-3/4" high x ~19-1/4" wide Bank 3 - 4 drawers - 3/4" PLY for drawer box and front / 1/4 Ply for drawer bottom - Drawer boxes are ~13-3/4" deep x ~27-1/2" wide and ~3-3/4" high - Drawer front is ~5-1/4" high x ~29-3/4" wide 4- casters ~5" high

[@michaelparker6081]

@@DIYwithDennis You are awesome! Thanks so much for the measurements!

[@DIYwithDennis]

@@michaelparker6081 no problem at all ..... good luck with your project!

[@daniellweber2003]

Hi Dennis, would you be so kind to provide me with the dimensions of the assembly table? Thank you in advance! Daniel

[@DIYwithDennis]

Hi Daniel, here you go: - Legs: 29" in length - Casters: 5" high - Long side of the table from outside leg to outside leg: 76" - Short side of the table from outside leg to outside leg: 34" - Top: 94" long x 42" wide + 3/4 edge banding all around (top consists of 1 sheet of 3/4" plywood + 1 sheet of 1/4" hardboard) - Overall height of the table: 35" Let me know if you need more. Best Dennis

[@daniellweber2003]

Hey Dennis, great ... thanks a lot! Best Daniel

[@billinfarmington5189]

Did you glue the hardboard on top? Thanks, Bill

[@DIYwithDennis]

Hi Bill, no, i didn't use any glue or any type of fastener on the interior of the hardboard .... I used 16 gauge nails around the perimeter of the hardboard close to the maple banding .... but that's it, and it lays nice and flat on the underlying plywood. My thought when doing it that way was that the hardboard may get 'beat up' over time and this approach would make replacing it pretty easy. Thanks for watching and good luck with your woodworking!

[@entrapment55]

looks great, finish? you most likely have done that. but not, then several coats of shellac, dries very fast to build a few coats, then some paste wax like Johnsons.

[@DIYwithDennis]

Thanks Ronald! Appreciate the feedback! Actually, I haven't applied a finish yet but I need to do so soon. Thanks for the recommendation!

[@joelterrishafer6713]

Nice job!

[@DIYwithDennis]

Thank you! Much appreciated!