Assembly Guide: Workbench E Single Deck Without Caster Installation Steps

What You'll Need Before Starting

First things first: Let's make sure you have everything you need. Grab a clean, flat workspace (a concrete floor or large table works best) and gather these tools and parts. If something's missing, check the packaging again—sometimes small parts hide in the corners!

Step-by-Step Assembly Instructions

1. 1 Unpack and Inspect All Parts

   Open the packaging carefully—those aluminum tubes can roll away if you're not paying attention! Take out each part and lay them out in groups: vertical tubes, horizontal tubes, joints, brackets, screws, and the deck.

   Give everything a quick once-over. Check for dents, scratches, or bent joints—if something looks off, reach out to your supplier (that's us!) for a replacement. Better to catch issues now than halfway through assembly.

   Pro tip: Take a photo of the parts layout with your phone. If you get interrupted, you'll remember where everything goes!

2. 2 Build the Bottom Frame (Base)

   Let's start with the base frame—it's the foundation, so we need it square and sturdy. Grab two 800mm horizontal aluminum tubes and two 600mm horizontal tubes (yes, we forgot to list those earlier—oops! They're the shorter ones for the front/back of the base).

   Take an internal rotary aluminum joint and slide it onto one end of an 800mm tube. The joint has a small lever—leave it loose for now so you can rotate it. Do the same for the other end of the 800mm tube. Now, attach a 600mm tube to each joint, making a rectangle. Tighten the levers just enough to hold the shape—we'll fully tighten later.

   Repeat this to make a second rectangle (this will be the top frame). Now you have two rectangles: one for the bottom (base) and one for the top.

   Pro Tip: To check if the rectangle is square, measure the diagonals. Both diagonals should be the same length (for 800mm x 600mm, the diagonal is ~1000mm). If not, gently push/pull the corners until they match—this prevents a wobbly frame!
3. 3 Attach Vertical Tubes to the Base Frame

   Now, let's stand the frame up. Take the bottom rectangle (base) and place it on the floor. At each corner, you'll attach a vertical aluminum tube (the 1200mm ones).

   Slide an internal rotary joint onto the top of each vertical tube. Then, align the joint with the corner of the base frame. Push the joint onto the base frame's tube end until it clicks into place. The great thing about internal rotary joints? They rotate, so you can twist them to get the vertical tube perfectly straight.

   Do this for all four vertical tubes. Now you have a "table legs" setup: four vertical tubes connected to the base frame. Stand back and check—all tubes should be straight up and down (no leaning!). If one's wonky, loosen the joint, adjust, and retighten.

4. 4 Add the Top Frame and Secure All Joints

   Remember that second rectangle we made (the top frame)? Now's its time to shine. Lift it onto the top of the vertical tubes—this will be the upper support for the workbench deck.

   Slide the top frame's corners into the internal rotary joints on top of the vertical tubes. Again, use the joints' rotation to align everything. Once the top frame is level and the vertical tubes are straight, it's time to tighten all the joints.

   Take the hex key and turn each joint's lever clockwise until it's snug—don't over-tighten (you'll strip the threads!). Go around the frame twice: first a light tighten, then a final check to make sure all joints are secure.

   Give the frame a gentle shake. It should feel solid—no wobbling, no creaking. If it moves, check the joints again—you might have missed one.

5. 5 Install Aluminum Profile Accessories (End Caps)

   Small detail, big impact: end caps. Those basic aluminum tubes have sharp ends, and the end caps cover them to prevent scratches (on you or your tools).

   Take an end cap and push it firmly onto the end of a tube—you'll hear a "pop" when it's seated. Do this for all eight tube ends (four on the base, four on the top frame). They're small, but trust us—you'll be glad you did this when you're sweeping up later and don't find a rogue aluminum burr on the floor.

6. 6 Mount the Workbench Deck

   Now for the star of the show: the workbench deck. This is the flat surface where all the magic happens, so we need it level and secure.

   Flip the frame upside down so the top frame is on the floor (this makes mounting the deck easier—no balancing act!). Place the deck on top of the frame (which is now the bottom, since we flipped it). Align the deck so it's centered—there should be equal overhang on all sides (about 50mm, if you're curious).

   Take the mounting brackets and screws. Position a bracket at each corner of the deck, where it meets the frame tubes. Use the hex key to drive the screws through the bracket and into the deck. Do this loosely first, then tighten once all brackets are in place—this ensures the deck doesn't warp.

   Flip the workbench back over (get a friend to help—deck + frame = heavy!). Stand it up and give the deck a little push—no movement? Perfect.

7. 7 Final Check and Adjustments

   You're almost done! Let's do a final walk-around. Check that all joints are tight, the deck is secure, and the workbench stands level. If it rocks, adjust the feet (if yours has adjustable feet—some models do!) or add a small shim under the base tube (a piece of cardboard works in a pinch).

   Wipe down the deck with a dry cloth to remove any dust from assembly. Now, stand back and admire your handiwork—you just built a lean pipe workbench from scratch! High five yourself—you earned it.

FAQs: Common Issues and Fixes