2x4 Workbench Corner Brace

I've got a new workshop, and was building some simple workbenches out of 2x4s and OSB. I've done this work before, and it's not that tough, but it's always a chore to line up and square everything. So, I ran across these workbench assembly kits online for $45.00 USD. They contained 8 corner braces that you just slid the 2x4s into, and it made everything super simple. Each kit lets you assemble one workbench with an under-shelf.

So, of course, I thought I'd see if there was a replica online. I found one, but I wasn't super happy with them.

• I printed 8 of them before realizing that the model needed to be flipped for half of the prints. This was not indicated anywhere on the page.
  • This is because the model is open on one side. I understand the design decision to avoid overhangs and bridges, but it made the model a bit problematic.
  • The model is thin and flexes when screwing in boards.
  • The dimensions for the 2x4 inserts are a little too generous, causing a very loose fit. This, and the open sides, caused a lot of extra care and work to make sure that everything was square before screwing in.
  • Pointy finish on the exterior side, making it uncomfortable to lean against while using the workbench.
  • The screw holes are too close to the ends of the boards. Several boards split while screwing them in.

So, I did what I always do when I want something better: I paid for a professionally designed model, got out my calipers, and went to work.

My design features:

• Thicker walls
• Screw holes further away from the board ends.
• Walls on all sides, allowing you to print 4 or 8 identical braces and flip them at need.
• Rounded/fillet finish on the outward-facing corners.
• Tighter tolerances.
• A very close facsimile of store-bought.
• Can print for about $1.00 a brace if you use cheap filament.

How to build a workbench:

Since my model is functionally identical to store bought, you can use the directions found online here:

https://buildheavyweight.com/wp-content/uploads/2019/10/2X4WRKBNCH-GRY-310685-Instructions-0819.pdf

or watch this YouTube video:

Supports are turned on in the Bambu Studio 3mf file.  They aren't required if you can live with the bridging defects. Those bits will be screwed to a board and won't be seen anyway.