DIY 80/20 Aluminum Desk Plans

The DIY 80/20 Aluminum Desk - durable, lightweight, and minimalist.

Do you need a workspace? This DIY project design looks great in multiple environment types, while still offering the kind of rugged functionality that only comes with 80/20 aluminum systems.

80/20 aluminum is known for being rugged, durable, and easy to clean. The aluminum resists rust and corrosion, and its strength-to-weight ratio is industry leading. In addition, modern 80/20 extruded systems are affordable, customizable, and widely popular. Add a spill-resistant acrylic top to it – and well, what better materials to build a desk out of?

And this one even rolls! No more heavy lifting when it comes to moving day, or even just rearranging the home office. In fact, these kinds of desks are widely used in modern office environments, thanks to their easy portability and modular utility value.

Ideal for: home offices, workshops, DIY projects, small businesses, and more.

Ready to get started on your own desk project? Great! Just check out the DIY build guide and diagrams below to get started.

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80/20 aluminum desk 3D render, second view

80/20 aluminum desk 3D render, third view

How to build a desk

Step 1

The first step is to build the base and support structure for your new desk. And it’s always a good idea to make sure that you have a large flat working surface – like a big table or some floorspace – and all your materials and tools in one place before starting.

First, lay out the base materials as seen in the diagram above. You’ll want to attach the two 30” T-Slot Rails to the longer 47.5” rail first, using Angle Joints.

Then, go ahead and attach the 27” rails to the bottom of the 30” rails at right angles (using Angle Joints). It might help to lay the already attached structure down for this step.

Next, attach the 6.25” Diagonal rails to the corners so that the right angles are braced.

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Step 2

Now, it’s time to build the top frame of your desk.

On a flat surface, connect the two 49.5” rails and the two 23.5” rails in the form of a rectangle, using Inside End Joints.

At this point, you’ll want to stand your desk base up and attach two Angle Joints to the tops of it, as seen in the above diagram. Then, go ahead and install your desk frame on top of these, taking the time to position it as needed, and making sure that it’s lined up.

Finally, install the two 20” Diagonal braces underneath to give your desk the strength and stability that it needs.

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Step 3

Almost there!

To install your paneling, first attach the solid panel hangers on top of each corner of your desk, facing in. Then, attach your 4x2’ acrylic panel to these. And please, take care not to overtighten these connections, as acrylic can crack if handled improperly.

And now, you can add your wheels! It might be easier to flip the desk over to accomplish this.

And of course, don’t forget your bin box holder.

And that’s it!

Congratulations! How does your new desk look?

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