Outdoor workbench build

My trusty ol' workbench got the facelift it deserved. 

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First step to this project was disassembly...not as easy as I woulda expected.

I wanted the 4x4's to be as flat as possible on all sides for tighter seams and a flatter top. I don't have a jointer or planer so I had to make due with what I had. I attempted to rip the face off of each board side with my table saw but to my discovery...it wasn't goin that well. My poor table saw just wasn't having it.

It dawned on me that I do have a little electric Craftsman planer so I scrapped the table saw idea and started planing down each side the best I could. Just kept making passes and checking the flatness with a 4' level.

After planing the best I could, I began drilling all the pocket holes...hole after hole...after hole. I ended up doing a set on each end and in the middle of each board. 

Glue up, lots and lots of glue. Since this bench is outdoors I used Titebond III. It's a water proof exterior grade glue.

I threw every big clamp I had at this thing. Only had 4 parallel clamps and added a couple 36" F style clamps to squeeze it as tight as possible. I know...I need more clamps.

Screwed in all my pocket hole screws before leaving clamped up overnight.

I built a new bottom frame that would help support the legs as well as reinforce the top even more. It was glued then pocket hole screwed to the top.

I cut my legs to their new size, accounting for the size of the casters I'm putting on this beast. Glued, screwed, and pocket hole screwed...they're solid.

Built my bottom framing that wraps around. Making sure these legs are sturdy and won't rack on me.

Time to add the swampers to this thing. I used 8" casters to make sure this bench will go anywhere I tell it to. For installation I used thread in nut inserts with bolts. I had to make my own washers out of aluminum flat bar...gotta get creative when you don't have what you need.

I went back and planed the top...over and over again, untill I got it as flat as I could. Gave it a nice sanding with 220 till she was nice and smooth.

I applied timber oil for a beautiful color and experimented using flex seal clear liquid on the top work surface. It didn't come out perfect but it's an outdoor workbench, what ya expect. It will definetely be better protected and should last me for many more years to come.