Workbench Tool Tray - Simple Add-on

Rob Cosman shows you how to build a simple workbench tool try and add it to his Cosman Workbench. Even if you don't have a Cosman Workbench you can use Robs techniques to build a tool tray for your workbench. Of course there will be dovetails in Robs Workbench tool tray!
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* VIDEOS ROB MENTIONS IN THIS VIDEO
- HAND CUT DOVETAILS: • How to Cut Dovetails b...
- SAWING SECRETS FOR BETTER DOVETAILS: • The Cosman Workbench -...
* ROB'S ONLINE WORKSHOP - robcosman.com/...
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* VISIT OUR STORE - To learn more or purchase any of the tools you saw Rob use in this video, please visit our retail store at www.robcosman.com
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[@RobCosmanWoodworking]

The Cosman Workbench: kzbin.info/www/bejne/hWHOf2SLh6eIi7M Workbench Sharpening Station: kzbin.info/www/bejne/hmHCY5WGr7B6ZpI

[@stanmoderate4460]

Did anyone else notice, Rob measured the bench at 60", said we'll come in 1/2" either side so that's 59", then made the shelf 58"? Looks great any way Rob!

[@bigkiv47]

Yep I was waiting for the blooper but it ended up pretty good lol so much going on in his head at once something has to slip now and again lol

[@weibullguy]

Just like watching a horror movie. As soon as he said 58", my brain started yelling, "Don't go there! It's 59", 59" not 58"!" I made the same mistake just yesterday on a shop cart, I cut the top an inch too narrow; even had the right dimension on my cut list. It makes me feel a little better knowing even the best sometimes end up an inch short!

[@stanmoderate4460]

I'm sure Rob had a mmmm? moment when he saw the larger gap at the ends.

[@HB-jd3ko]

Yes. He also measured the depth of the apron at three inches but didn't add the thickness of the rebated ply base. The top of the tray, therefore, sits lower than the bench top. Not a problem but I intend to make mine finish level as with his other examples.

[@BigBuddiBlax]

59” is overall… the bottom ply is rabbit 🐇 into side pieces which would make it 58”…. If he does exactly like the student demo piece…so much knowledge and gems being given here.. spoken and unspoken… seems like a strange thing to focus on and then the “ looks great anyway ROB ( even though you gave one wrong number (possibly)and I messed up because I won’t spend money on the plans OR possibly I don’t know what I’m doing and instead of concentrating on building a fundamental skill set so the numbers you give don’t matter.. because i may not have a 60” bench anyway🙄)… is pretty petty😒…I guess suckas are allowed to watch KZbin as well… happy woodworking ✊🏾✊🏾✊🏾..Mr Cosman …. You are a treasure … appreciate you!!!

[@larrypostma2866]

You hear Rob talk about his difficulties seeing often but don’t appreciate it’s meaning until you get to look through his glasses. I’m pretty sure as we were looking over his shoulder I saw mercury through those things.

[@processpsych]

It's good to know that even Rob Cosman runs a board on his router Table, and has to figure out how not to hit his jointer right next to it. I am not alone in the world!

[@DustyFixes]

You just brought back a memory from when I was a kid. My dad took me to a wood shop somewhere in Northern Utah where we lived. I remember the guy was cutting something into the end of the board. Probably dove tails, but I don't know for sure. Anyway, under the bench vise was a cutout in the wood floor and a hole in the dirt about 3 feet deep and the piece he was cutting went down into the hole. Wow, I haven't thought about that for years. lol

[@RobCosmanWoodworking]

Yep thats the set up I had in my old shop

[@jeffschiavi3368]

Rob, I don’t think I’ve ever seen your bench and tool tray so clean!!!

[@RobCosmanWoodworking]

Hint....i didnt clean it out, someone else did!!!!

[@jeffschiavi3368]

@@RobCosmanWoodworking If I’ve learned anything from watching your videos, I would feel safe betting that it wasn’t Super Dave

[@thatsthewayitgoes9]

Turn bench upside down on flat floor. Make left & right 1”x 3” x 30” oak (or however deep you want the bench width). Glue/ screw each of these to each bench end. The floor will make these perfectly even with bench top. Cut oak or ? 3”x3” to fit between these extensions. Glue / screw this , on the floor, between the extensions. The floor will make perfectly even with bench top. Done. Put your choice of panel on bottom. After dry up, knock your socks off by replacing screws with driven in glued wood dowels.

[@JamesWilliams-en3os]

Thanks for demonstrating the technique for cutting dovetails in long boards. I’m building a 70” shelf to sit on top of my reloading bench, and was scratching my head trying to figure out how to cut the tails/pins on the ends of that long oak plank. Now I know not just how to cut them, but also know to cut the tails into the long piece, then mark and cut the pins on the shorter pieces that will form the uprights.

[@jimmysiniawski7391]

I’m glad you mentioned that . I never realized that a board after ran through a jointer or planer wasn’t flat. And hearing the plane skip was really surprising once I got into using my plane thanks to you.

[@RobCosmanWoodworking]

Most folks dont realize that. You now have the power of knowledge

[@joehirschegger7723]

Very timely video...just finished my Cosman bench and was just planning to add a tool tray!

[@RobCosmanWoodworking]

Yes I sensed that so I made thisvideo for you!!!!

[@WiscoWoodShop]

Yep, I have my MDF top built. I had to do mine out a 3/4 but I made it work. It’s a great top it looks fantastic.

[@RobCosmanWoodworking]

Nice.....Now time to add a tooltray

[@TREBORANDERSON]

I'd like to see one of these tool trays attached with a french cleat. This would make it easier to empty dust and shavings, or remove altogether if required ... regards from Scotland.

[@stanmoderate4460]

I was thinking of a way to make it removable for ease of cleaning. Describe French Cleat (sorry for the two 'thumbs down' that was my fat finger error!

[@stanmoderate4460]

Hi Trebor, I found the description of a French Cleat! I have used them before, just did't know it was called that! Hi from a Gordie in Australia

[@RobCosmanWoodworking]

That could work

[@yaucalabi]

Perfect timing. Have discovered first hand that I really want to add a tray to my cosman bench. Great up close video. Great instructions

[@RobCosmanWoodworking]

Now you know how to do that

[@andrewbrown8148]

Simple is right~! I'll be measuring up my Sjöberg bench this weekend for a tool tray. Will be nice to clear the top and have the items close at hand without them being underneath the bench top. Thanks, Rob~!

[@terenceleonard7724]

Looks great Rob. Practical and not over engineered

[@robertbamford8266]

Always a pleasure to watch you work - especially as you explain and sometimes evolve your solution. Particularly appreciated the way you completed the routed corners with a cut on the first edge to the line for the second edge.

[@RobCosmanWoodworking]

Hope it helps you

[@sueb4154]

You make everything look so easy! I do not understand how you can rout the inside of a frame, without being able to see the router bit or the surface being planed. You are incredible to watch, and if I master one thing that you have taught me, I'll be happy! Great video, great bench ... (although your maple bench is the BEST ever)!

[@RobCosmanWoodworking]

I am using a router bit with a top bearing so I dont need to see the blade just the top bearing

[@leehaelters6182]

That would be a god-like skill for sure.

[@montyswoodworkscrafts2232]

Great video, think its the most times I ever seen Rob using power tools

[@RobCosmanWoodworking]

Its a new fad!!!!!

[@tinyvanderwesthuyzen6513]

OUTSTANDING. Your work is incredible

[@murphymmc]

Great add on. FYI Studies have shown 12 lbs. of pressure to run a Phillips screw in, 8 lbs for a Robertson, 5 lbs for a Torx. Test it and see. Another side benefit of Torx is that a size smaller bit will work on a screw ( no excessive torquing now) when to don't have the correct one, in a pinch. Yeah I know, there's a peculiar loyalty to the Canadian invented Robertson screw, I switched to them years ago when I got absolutely frustrated with Phillips head. Then I discovered the beauty of Torx. Like the Square drive, you can grind a bit off the tip when it gets worn, a big plus, you certainly won't get away with that in a Phillips head.

[@RobCosmanWoodworking]

I prefer the Robertson screws because unlike a torx the Robertson will stick on the end of a robertsonscrewdriver and you only need one hand. Torx wont do that.

[@joew694]

Perfect timing! I've been wanting to make one for my bench. Good stuff Rob!

[@RobCosmanWoodworking]

I nee you were so I made this video!!!!!

[@joew694]

@@RobCosmanWoodworking Well if I had to have someone crawling around in my mind, I’m glad it was you and not somebody else🤣

[@jamesw4850]

Lady at the the door near the end "Aren't you finished yet? You said you would be done 20 minutes ago... When are we going to go eat!" At least that is what my wife would be saying.

[@tomsatterlee8397]

Hello Have watched a number of your video and I do like your style. As with anyone doing something I could make some comments but I would never do that with a person with a somewhat different way of doing things which would do nothing to further a good comment. Love the appearance of your shop and would enjoy learning more of you operation. Thanks

[@leehaelters6182]

35:50, we’ve all been there. Soldier on, Rob.

[@RobCosmanWoodworking]

Roger that

[@antipodesman]

I wondered if I was the only one who saw that . . . 😕

[@billcummins9579]

that's really nice.. I need to make one. I have been thinking about it for a while. I'm always making things, for everyone else but myself.

[@RobCosmanWoodworking]

I know exactly what you mean!!!!

[@kiwdwks]

Always learn something...thanks Rob!

[@RobCosmanWoodworking]

Welcome

[@mikaelfischer8429]

Thank you Rob for sharing this. This will be a pretty cool addon to my bench I am going modify.

[@RobCosmanWoodworking]

Glad you can use it

[@FranksDIY]

Great timing. I will be starting to make my bench soon and wanted a tray but was not sure on how I would go about it. Thank you love this method Rob

[@RobCosmanWoodworking]

I knew those were your plans soImade this vidoe for you!!!!!!!

[@kyvguinto]

Man, remember that hole you had in the floor of your last shop for dovetails on long boards? Always thought that was a cool feature.

[@RobCosmanWoodworking]

Only reason I miss the old shop occasionally!

[@shanejohnson800]

Your a beast rob!!!

[@MANJITSINGH-ko2oi]

COOL shelf.

[@RobCosmanWoodworking]

Thanks

[@SnapographyAP]

Working in inches is insane:-)

[@RobCosmanWoodworking]

Or another way of looking at it is not for the mathematically challenged!!!!! : )

[@danaparish1644]

Made your bench...Glad you’re showing this! I’ve got the 5 1/2 Jack Plane and love it too.

[@RobCosmanWoodworking]

Sounds lik etwo good decisions.....Nowfor a tool tray

[@kainemeshkin6662]

Informative video, as usual. Thanks for the tips!

[@RobCosmanWoodworking]

You are most welcome

[@garrettdillon4820]

Hell yeah! I’ve been wanting to add one to mine awesome bench I’ve really enjoyed using it and the price of it

[@RobCosmanWoodworking]

Thanks. Please go to the DVD on our webpage and give us a review

[@RobCosmanWoodworking]

Now you can!

[@hassanal-mosawi4235]

well done! thanks for sharing that

[@RobCosmanWoodworking]

Thanks for watching

[@panos3051]

Rob is so accustomed to the natural way of cutting dovetails that at 8:16 he still says "careful not to go below my line" although in this case it's actually "past", not "below"!

[@RobCosmanWoodworking]

Good point

[@roncrandall]

I've received that same look from my wife when I've spent more time in the shop than I said I would.

[@dmac3682]

This will be my first dovetail project. Novice question: could you cut the rabbet prior to cutting the dovetails so you could do it with the boards face down against a fence instead of balancing the completed frame like you did? Just not cut rabbet into where the dovetail would be and mate the corners with a chisel? This will be a great addition to my workbench.

[@DianneCarrington]

Rob, just a joy to watch you work, you are so inspiring. Based on your videos I am going to do the types of projects I did in my 20s in my late 60s. I thought I was past this, but you inspire my confidence. You used 2 clamps that I can't see on your online store. The first was the "ratcheting" clamp @ 23.35m and the 2nd was the "deep" clamp @ 34.15m. Are these on your online shop?

[@RobCosmanWoodworking]

We dont sell any clamps in our store. Those are Bessey clamps newer line of ratcheting clamps

[@DianneCarrington]

@@RobCosmanWoodworking Thanks for responding

[@panos3051]

Speaking of "unnatural way", at 12:15 I really had to pause for a moment to come to grips with seeing the pins being hammered into the tails rather than the other way round!

[@RobCosmanWoodworking]

It was an alternate universe of dovetails

[@joschmoyo4532]

There is nothing wrong with cutting a rebate for the bottom but I would have cut a groove and fitted it like a drawer bottom. Stronger that way and you don't need to pin or screw the bottom in place. Mechanical strength is always better than relying on just a glue line.

[@jeffreyglaude5937]

what are those ratchiting clamps you use to hold the shelf while you drill etc...?

[@paulkern3848]

What are the measurements for the board you attached to your trim router? Thanks in advance!

[@solotheater]

wait! it's only fastened from the bottom? I love your channel, it's become my #1 procrastinator destination, But, only fastening from the bottom seems like 1 ham-fisted lean away from a structural failure, no?

[@johnburens3395]

Just a suggestion here for the tray mounting. My Moravian workbench has a removable tool tray which is a nice feature.(the whole bench knocks down in a minute or two) Having looked at your bench I think you could do this with some beefy dowels glued into a block of wood and screwed to bottom of the tray. Of course you would have to bore a few holes into the bench itself and then the tray could slide in and out when you want to empty shavings. A couple of pins in the back side would keep the tray from sliding out unexpectedly. Just my thoughts on how I would do it...

[@luxlarryj656]

First thanks for your great advise and easy to follow videos. I've been thinking of adding a similar tool tray to my own bench, but was thinking of a 4-sided box-like arrangement that would be level with the benchtop (bolted or screwed in place), and could support wider materials on the benchtop. The student version of the tray appears to be benchtop level and yours is a little lower, please comment.

[@matthewransom6469]

Can you make this bench wider and longer and it be okay? I'd like to do one but I need one little over 6 feet long and 3 feet wide. Can I do that and it be okay??

[@lanecobb4150]

Was there a reason the 1/2” thickness of the bottom plywood was not added to the width of the 2 ends and the long back piece so the tray would have ended up flush to the top of the bench? Doing so would have made the tray depth a might deeper, effectively added to the overall width of the bench top and allowed clamping along the tray side of the bench.

[@RobCosmanWoodworking]

Because I screwed up.

[@chrisfleming7288]

Great vid! One question: why not make the tray edges flush with the bench top? Then it would offer a level edge support for materials when they project beyond the back bench edge. Maybe because of the rounded over top edge?

[@RobCosmanWoodworking]

Because I screwed up the measurements. Forgot to account tor the bottom going under the bench. The sides should come up flush

[@chrisfleming7288]

@@RobCosmanWoodworking Please don't take this the wrong way, but it sort of gives me pleasure to know you make mistakes! Love all you do!

[@RobCosmanWoodworking]

No worries! I make lots of mistakes

[@fa256b7]

👍👍👍👍

[@yusufemrahsimsel]

35. 55 i know this looking:)

[@vincentfaure4472]

I wonder if the video editing chief drinks only maple syrup... However thank you for the job, very informative.

[@illiesjammin]

How thick is a window frame?

[@Lordac]

what are those one handed clamps called?

[@robertbamford8266]

Never on the floor (almost never)! On top of workbench always in the way.

[@RobCosmanWoodworking]

In the tray is much better

[@skf957]

Anyone else get sucked into a wormhole at 34:45 back to 34:00? Thought I was in for the duration on a 45 second loop. What a life.

[@RobCosmanWoodworking]

What? Is there an issue with the edit?

[@skf957]

@@RobCosmanWoodworking You'd probably know better than me whether its an edit issue or just a planned repetition. It starts at 33:38 when you fix and tap the tool tray into place, comment about not screwing through the dog hole, place the central clamp and drive in an overly long screw. Then the process of attaching the tool tray kind of starts again - but with shorter screws. Sounds like I'm being picky - and I really am not. I get a lot from your content, and appreciate the considerable effort that goes into making it.

[@leehaelters6182]

@@skf957 , he just moved down the bench to the next spot to need a screw.

[@skf957]

@@leehaelters6182 I've looked at this 3 times now and am perfectly fine with missing something - as I often do! BUT, to my eyes there is a repetition of the action. The "first" fix of the tray ends with the comment that the screw is too long. The second go is the the one where the door behind opens and Rob is photo bombed!

[@leehaelters6182]

@@skf957 I copy, and do not refute.

[@revtoiletduck]

Great timing. I just bought the plans for the Cosman Bench and will be building it in December. How do you get such clean jigsaw cuts on plywood? Just a good quality blade?

[@RobCosmanWoodworking]

exactley, and good plywood (Baltic birch)

[@leehaelters6182]

@revtoiletduck, if you are getting too much splintering with yours, just knife that line.

[@magicdaveable]

Splined construction fasteners are much more efficient than Robertson Drive fasteners and much less likely to strip.

[@RobCosmanWoodworking]

I dont think I agree with that....Maybe I shoudl do a test?

[@leehaelters6182]

@@RobCosmanWoodworking, Rob, fertile ground there. Everyone would appreciate practical data on that subject!

[@danielgeng2306]

Hey Rob, could you also put a long board on a saw bench ? I’m thinking it may be easier because you’re over top with your knee on the board , or would it be to difficult to see the layout lines on the end ?

[@RobCosmanWoodworking]

Thats a great idea....better than what I did

[@danielgeng2306]

@@RobCosmanWoodworking hey boss, even a blind squirrel finds a nut once in a while ! Lol have a great day my friend!

[@ricos1497]

@@danielgeng2306 Good solution. I was hoping to see Rob do a double legged jump onto his workbench with a perfect landing, before sawing the board in his vice from above, supporting with his knee. Next time.

[@Firefoxtony]

Rob none of the people watching a video for woodwork this simple have a router table. Why do half with hand tools and the rest with massive machines? I do appreciate your work a lot but maybe consider doing a video just completely with machines or completely with hand tools for a different audience 😉

[@Brough_builds]

Would it be possible to add a solid wood (hardwood) frame around the cosman bench to add a shoulder vice?

[@RobCosmanWoodworking]

All shoulder vise construction like on my bench is difficult. Yes it could be done. Need to add in the long standard bolt. I have never done it with MDF so I cannot be sure of the results

[@Brough_builds]

@@RobCosmanWoodworking ill give ot a try when I get around to building my bench in the new year. I'll let you know how it turns out

[@philipchandler330]

Quite a look your wife gave you!!

[@bigkiv47]

LOL just watching Rob add imperial measurements makes me wonder why do you still use imperial.... 150 mm plus 27 mm = 177 mm rather than 5 11/16 + 1 1/16 = 6 12/16 or 6 3/4. seems so complicated but then if you have always used it it is simple enough. Will be making the bench soon so this came just in time. I was going to make my top out of 4 x 25 mm ( 1 inch) MDF with the bottom piece being 150 mm (6 inches) wider to form the bottom of the tray area then glue and screw dovetailed pine around it but this way is probably better and can be replaced easily after time. thanks Rob :)

[@RobCosmanWoodworking]

Glad the video was helpful. The base 12 measurement system (imperial) was originally designed for a population of craftsman who had no mathmatical skills and need an easy to use basic system. Its only now that we all go to shool and learn math that a base 10 system is easier to comprehend. for example: in a base 12 system- whats a fourth of 12, whats a 3rd of 12, whats half of 12, whats a 6th of 12. In a base 10:whats a forth of10, a 3rd of 10,half of 10, a 6th of 10!!!!!!! I am a history nut. Read, By hand end eye" formore detaisl.....Just thought you would be interested.

[@bigkiv47]

@@RobCosmanWoodworking yeah mate.... we converted to metric in 1974 here in Australia and I found it weird at first but even today I still use a mix of metric and imperial in daily life. Metric for lengths of timber but I still refer to widths in inches 2 x 4 etc but 1.8 metres long. lol So I supposed I am probably more screwed up than you guys lol ;) but in saying that I only buy tapes that are in metric so as I don;t get further screwed bwaaahaa

[@tchevrier]

for a workbench I would be a little concerned about how strong that is attached to the bench.

[@cbryantbear6498]

Sorry i missed this, did you use CA glue for the bottom?

[@brianmiller6304]

regular wood glue

[@danthechippie4439]

Hi Rob, what finish do you use on the MDF top?

[@RobCosmanWoodworking]

Tung oil or spray lacquer

[@WiscoWoodShop]

Rob, I noticed in one of the other videos that you mentioned that you worked with woodriver several years ago to develop their bedrock plane. I noticed Rex Krueger mentioned in the last day or two on his tool review that he was disappointed that woodriver had stolen the work of Lie Nelson. That seems like quite an accusation to me. I wonder if there is more to that story that you could share with us. It seems to me that if you helped them develop it but it was not stolen from Lie Nelson but developed from the original bedrock plane.

[@RobCosmanWoodworking]

WoodCraft hired me to consult with them to improve their WoodRiver planes. Before that I was Lie Nielsen's sole sales representatiove in Canada for 8 years. Bot Lie Nielsen and Woodcraft tood the Stanley Bedrock design (which patten had long before expired) and each independently designed and improved plane based on th ebedrock design. Any other,I was there and taht is what happened.

[@RobCosmanWoodworking]

Jason....so which Rex Krueger video (video title) does he say that so I can watch the context please

[@wolverinebear5357]

Cant steal from a expired patent its fair game, only thing i wish was woodriver was atleast North American made, still great plane for the price.

[@WiscoWoodShop]

@@RobCosmanWoodworking I am glad to hear that. That is what I have understood from all of your other videos. If I haven’t watched all of your videos I’ve watched almost all of them anyway. Both you and Rex offer very practical advice for beginning, average, and experienced woodworkers. I was surprised that he would make that sort of claim. I was disappointed to hear Rex do that. Regardless, I love your work and I love what you do for vets. I appreciate your development of your videos and how you are willing to make anyone a good dovetailer. Keep up the good work. We love you and your crew. You have been great through Covid as well.

[@revtoiletduck]

@@RobCosmanWoodworking It's here: kzbin.info/www/bejne/o5usd4qnoalmg5I

[@hellomate639]

Why don't you just add glue to the end grain spot? End grain joints aren't actually intrinsically weak. In fact, when people actually test them with load frames and load cells, the results show that that end-to-end bonds are significantly stronger than side-to-side bonds. The strength from joints like dovetails comes from the crossing direction of the cellulose fibers. But time and time again, miter joints are also stronger than dovetail joints, and when dovetails fail, they fail as if they were a square joint, where the wood slides out of the triangular portion like a sheath. One theory for the "end grain is weak" myth is likely that when people break these end-grained joints, they remove the glue, so people think the joint was weaker, when in fact, the torque from the end-to-end bond was actually significantly higher. Same thing goes for miters. Glue is stronger than lignin, the wood's natural glue that holds the cellulose fibers together, but it is far, far weaker than cellulose fibers. This is why side-to-side joints probably evolved over end-grain joints. But the misconception spread that the bond between end grain is weak. It's actually very, very strong. It's just not as strong as cellulose, so there's not as much of a point to end-grain gluing. They also don't "sop up glue" as much as people think, because the glue is so viscous. Even if it was weaker, it can only add strength in this instance.

[@santhony74]

is that a 3/16 roundover?

[@RobCosmanWoodworking]

YES

[@davidpisarski5620]

Hi Rob, What grain rasps would you recommend to start with? I do not have any rasps only metal files.

[@RobCosmanWoodworking]

1. A cabinet rasp with fairly coarse teeth for stock removal. Recommended: 9″ Auriou with a 10 grain. 2. A modeller’s rasp with fine teeth for refining shapes. Recommended: 6″ Auriou with 15 grain. 3. A rattail rasp for coping inside corners and dealing with tight, radiused details. Recommended: 6″ Auriou with 13 grain.

[@davidpisarski5620]

@@RobCosmanWoodworking Thanks Rob.

[@tinywoodshop5491]

I guess it didn’t end up being flush with the workbench top!

[@RobCosmanWoodworking]

yea I screwed up themeasurement, didnt account for the plywood bottom going under the workbench so its 1/2 too shoet.....Still works, but good catch.

[@1striperon]

I am not a fan of the way the tray is attached to the bottom of the bench. Seems that weight in the tray would exert leverage against the screws, eventually prying the tray down. Maybe I overestimate the weight in the tray, Rob.

[@RobCosmanWoodworking]

We use them in our classroom. They’ve held up for five years without a problem.

[@Thyme2sea]

Who is there behind the door at 35:55?

[@marimehlen2813]

It look like his wife, her face said are you still not finished, have you forgotten you should help me preparing thanksgiving? Thank you for the time you teach us, it is fabulous and inspiring.

[@RobCosmanWoodworking]

Kim

[@johncawsey9999]

1 inch from 60 inches is 59 and not 58 ,get your maths head on rob