How to Build a T-Slot Aluminum Workstation Desk With a Light and Accessories Bar

This is a 75"w x 84"h heavy-duty modular workstation desk using t-slot aluminum, featuring a built-in light and a versatile accessories bar. The desk offers a sturdy, adjustable frame with an integrated lighting solution, providing ideal illumination for detailed tasks. The accessories bar adds customization options, allowing you to mount and organize tools, monitors, and other essentials. This design takes advantage of t-slot aluminum’s flexibility, making it easy to adapt and expand the workstation to fit various needs.

I bought this as kit on Parco: Workstation QD21864 for a customer. They have all sorts of pre-designed t-slotted solutions if you are looking for something similar.

Arrange the Extrusions

Begin by laying out two E1530G t-slot aluminum extrusions to form an "H" shape. These extrusions will serve as the main support attaching the leg assemblies, providing stability to the desk frame.

Pre-load the End Fasteners

Insert the T-slot fasteners into the appropriate slots of the extrusions before starting the assembly. Pre-loading the end fasteners allows for a much easier and efficient connection when attaching the pieces later.

Attach the Pieces

Align the two extrusions to create the "H" shape. Use the end fasteners to join the pieces securely. Ensure that the connections are snug, and double-check the alignment to maintain a square frame.

Prepare the E3030G Extrusions for the Legs:

Select the E3030G t-slot aluminum extrusions that will be used to form the legs of the workstation desk. These extrusions will provide the vertical support needed to hold the desk securely.

Attach the Connecting Piece (E1530G):

Take the E1530G extrusion and position it horizontally between two E3030G leg pieces. This E1530G will serve as a connecting piece that stabilizes the leg frame.

Assemble the Leg Frame:

Align the E1530G connecting piece with the two E3030G extrusions to form a sturdy "H" shaped leg frame. Secure the connections using the pre-loaded end fasteners, and tighten them to ensure stability.

Repeat for the Second Leg Frame:

Follow the same steps to create a second leg frame using the remaining E3030G and E1530G extrusions.

With both leg frames complete, you now have the vertical support structures for your desk. These frames will later be attached to the main desk assembly.

Prepare the Base Plates

Take the base plates and hardware that will be used at the bottom of each leg. These plates will provide a stable foundation for the desk, helping to distribute the weight and keep the structure secure.

Attach the Base Plates to the Legs

Position the base plates at the bottom of each E3030G leg. Use the socket head bolts to securely fasten the plates to the leg extrusions. Double-check the alignment to ensure the plates are evenly attached.

Install the Adjustable Height Stem

Insert the adjustable height stem into each base plate. The stems allow for fine adjustments to the height of each leg, which is useful for leveling the desk on uneven surfaces.

Adjust the Height

Once the adjustable height stems are installed, fine-tune the height of each leg to achieve a level workstation. This step is crucial to maintaining stability and ensuring a comfortable working height.

Prepare the "H" Support Piece

Take the "H" support piece, which consists of E1530 extrusions that you made in step 1 that will connect the two leg assemblies. This piece will provide horizontal support and stability to the table base.

Position the Leg Assemblies

Place the two completed leg assemblies parallel to each other. Ensure that the distance between them matches the length of the "H" support piece.

Attach the "H" Support Piece

Align the "H" support piece with the pre-loaded end fasteners on each leg assembly. Secure the piece and tighten them to ensure a stable connection. Double-check the alignment to keep the table base square and even.

Secure All Connections

After attaching the "H" support piece, verify that all fasteners are tightened securely and that the base is level. Adjust the height stems if needed to ensure the entire base sits evenly on the floor.

By completing this step, you have created a strong, stable base for the workstation desk. This forms the foundation for the rest of the assembly.

Create the Outer Rectangle Frame

Attach the Side Extrusions to the Top of the Legs

Start by securing two E1530G extrusions to the top outer sides of the E3030G legs. These side pieces will act as the main horizontal support beams, connecting the leg assemblies. Pre-load the end fasteners into the E3030G legs and use bolts to firmly attach these side extrusions.

Add the Two Inner Supports

Next, position two E1530G extrusions between the attached side pieces. These inner supports will add additional stability to the frame and help distribute weight evenly across the desk.

Complete the Rectangle Frame

Once the inner supports are in place, add the remaining two E1530G extrusions to complete the rectangle frame. Align these final pieces with the top of the legs and the inner supports. Pre-load end fasteners and secure the connections, tightening all points to create a rigid frame.

Double-Check and Secure All Connections

After the frame is complete, check all connections to ensure everything is tightly secured and the structure remains level and square. Make any adjustments as necessary.

By completing this step, you’ve created the main support structure for your workstation desk, providing a strong foundation for the tabletop or other features you plan to add.

Create the Back Frame

Use the appropriate t-slot aluminum extrusions to create a rectangular back frame that matches the width of the table frame. This back frame will support the lightbar and accessories.

Build the Lightbar/Accessory Bar Frame

Construct a separate frame for the lightbar and accessories using t-slot extrusions. Ensure that the lightbar is positioned at the desired height above the table frame. This frame should be sturdy enough to support mounted accessories or tools.

Attach the Lightbar Frame to the Back Frame

Secure the lightbar/accessory bar frame to the top of the back frame. Double-check that all connections are aligned and tight, as this will support the weight of both the light fixture and any additional accessories.

Attach the Back Frame to the Table Frame

Position the back frame against the rear edge of the table frame. Use gussets to firmly connect the back frame to the table frame, ensuring a strong and stable connection. The gussets should be attached to both the back frame and the table frame using pre-loaded fasteners.

Double-Check Alignment and Connections

Confirm that the back frame, lightbar frame, and table frame are all level and properly aligned. Tighten all bolts and gussets to ensure the entire structure is secure.

This step completes the framework for your workstation, including the essential lightbar and accessory mounting area. The gussets help reinforce the connections and provide additional rigidity to the entire desk.

Position the .25" Aluminum Bottom Plate

Begin by placing the .25" thick aluminum plate on the bottom section of the workstation frame. This bottom plate adds structural integrity and can serve as a storage or support area.

Align the Bottom Plate with the Frame

Ensure that the plate is properly aligned with the rectangular support structure and all edges are flush with the frame. Mark the points where the screws will be installed, using the pre-drilled holes in the plate or measuring evenly spaced points along the frame.

Secure the Bottom Plate with 1/4-20 Flat Head Screws

Pre-drill pilot holes into the frame, if necessary, to match the marked screw positions. Insert 1/4-20 flat head screws through the plate and into the pre-loaded T-nuts or threaded holes in the frame. Tighten each screw until the plate is firmly secured.

Position the .50" Work Desk Top

Next, place the .50" thick work desk top onto the upper rectangular frame. This thicker top surface will provide a durable and stable work area.

Align and Mark the Desk Top

Align the desk top with the edges of the upper frame, ensuring it is centered and properly positioned. Mark the screw positions along the desk top to correspond with the frame's slots or pre-loaded T-nuts.

Secure the Desk Top with 1/4-20 Flat Head Screws

Pre-drill pilot holes if needed, then insert 1/4-20 flat head screws through the desk top and into the frame. Tighten each screw to secure the desk top firmly in place.

Tighten All Hardware Connections

Go over every connection in the workstation desk, including the frame joints, leg attachments, gussets, and mounted plates. Ensure that all bolts, screws, and T-nuts are tightened securely. This final check is crucial to maintaining stability and safety for the entire desk.

Install Lights

If you have a light fixture planned, attach it to the designated lightbar or accessory bar. Follow the manufacturer's instructions for mounting and wiring the light. Position the light to provide optimal illumination for the work surface.

Add Accessories

Attach any additional accessories to the accessory bar or other designated areas on the desk. This could include tool holders, monitor arms, cable management clips, or other functional items.

Final Alignment Check

Once all lights and accessories are in place, perform a final alignment check to ensure the workstation is level and balanced. Adjust the height stems if needed to maintain stability.

Test the Desk Setup

Test the completed workstation desk by applying some weight or placing items on the work surface to check for stability. Adjust any components if necessary.

With all hardware tightened and accessories added, your t-slot aluminum workstation desk is now fully assembled and ready for use!

For t-slot parts there are a few different places online but I use Parco T-slotted aluminum because they have the best prices on American-made products and that is important to me.