How To Build A Bench

MATERIALS:

	10: 1x2x8 pine 2: 2x4x8 pine 1: 2x6x8 pine 2: 1x4x8 pine 1: can of stain 1: can of spar urethane 1: plastic bowl 2: 2x2x8 pine 1: box 2″ screws 1: box 2 1/2″ nails 1: box 1 1/4″ nails 1: box of rags 1: can mineral spirits 1: paintbrush

Table Saw Tape Measure Pencil Router Miter Saw Speed Square Compressor, Gun & Hose Extension Cord

STEP 1: Cutting The Bench Base

1. Take your 2×4′s and cut two of them 45 5/8″
   
   
   

2. Also cut 4 2×4′s 15″
   

STEP 2: Building The Bench Base

1. Attach your 2×4′s (I prefer to use glue and a nail gun but you can pre-drill and screw to attach as well)15″ long perpendicular to the ones 45 5/8″ 2 1/4″ from each end.
2. Attach the other two 15″ 2×4′s evenly between the outter two perpendicular to the 45 5/8″ boards till you have a base similar to this:
   

STEP 3: The Legs

1. Cut two 2×2′s 33″ long and two 2×2′s 23″ long
2. Measure 18″ from the bottom of all four and put a mark
3. Attach the 2×2′s on all four corners of the bench base. Matching heights in the back and matching heights in the front.
4. Make sure the top of the base is sitting at 18″ until it looks like this:
   

STEP 4: The Seat Planks

1. Cut 12: 1×2′s 45 5/8″
2. Apply glue to the top of the 2×4′s on the bench base and lay the 1×2′s across the seat area of the bench base.
3. Stack 1×2′s with no spacing because the wood will shrink over time leaving spacing.
4. Knotch 1×2′s around the 2×2 post for a clean look.
   

STEP 5: The Back Rest

1. Take a 2×6 and cut it 45 5/8″
2. Set you table saw blade 2 1/4″ deep
3. Set your table saw gauge at 1″
4. Notch each end of the 2×6 like the picture below:
   
5. Set the blade on the table saw at 1″ and the gauge at 1″
6. Stand the 2×6 on side cut the 2×6 full length with notched ends facing gauge.
7. Lay the 2×6 on the table saw, notched end down and previous cut end against gauge and rip full length
8. You should now have a 1×1 notch across the length and ends of the 2×6 all on the same face of the board.
9. Take your 2×6 and lay it flat, notched ends down.
10. Measure 3 1/2″ from the notched long side of board and put a mark on both ends
11. Measure 22 13/16″ from the end to mark center of the 2×6 still notched ends facing down. Then measure on center from the notched long end 4 1/2″ and put a mark.
12. Drive a screw into each mark
13. Take a 1×2 and use your screws as leverage to arch the 1×2 and trace like below:
    

14. Remove 1×2 and screws and cut arch with a jigsaw or skill saw
15. Now take router with whatever design bit you would like the finish to be and route a clean edge on the arch side
    

16. Take a 2×4 cut 45 5/8″ and notch the ends just like the notched ends of the 2×6.
17. Also notch the 2×4 length just like the 2×6
18. Take 2×6 and place it between the 2×2′s attached to the bench at the top so the 2×2′s don’t stick above it. Make sure the distance from the bench seat to the bottom of the 2×6 is the same on both ends
19. Also measure from the bench seat up 3 1/2″ on the 2×2′s and fasten the 2×4 like the picture below:
    

20. On the back side of the bench back measure from the bottom of the notch in the 2×4 to the top of the notch of the 2×6 and cut 14: 1×2′s at that measurement.
21. Fasten the cut 1×2′s 1 1’2″ apart working your way from the sides to the middle then split the difference on the middle two like the picture below:
    

STEP 6: The Arm Rest

1. Measure from your back 1×2′s to the front of the seat of the bench and cut 2: 1×4′s that measurement.
2. Dog-ear one side on each board by nipping a 45 degree angle off both corners on one end (make sure you do it evenly)
3. Fasten the 1×4′s on top of the front 2×2 (dog-ear to front) and back of 1×4 sitting on top of the 2×4 on the back rest(make sure arm rest sits even with the side of the bench. After they are fastened it should look like this:
   

STEP 7: Finishing Sides

1. Measure between the 2×2′s on the side of the base frame and cut 2×4′s to fill between and fasten in place
2. Measure from front base frame 2×4 to back and cut a 1×4 that will lay over the previous 2×4 and 2×2′s to finish off the ends
3. Repeat for both ends. should look like this:
   

1. Take 80 grit sandpaper and sand entire bench. Focus on rought edges and impurities in the wood. Try to sand with the grain
2. Blow sawdust off wood
3. Place bench on a tarp so you don’t get stain on the floor
4. Open stain and use paint brush to apply stain (do 1′ square area then take cloth and wipe stain) repeat till entire bench is stained
5. After stain has dried 4-6 hours its time to seal
6. Take your Spar Urethane and brush
7. Apply an even thick coat of Urethane over stain on entire bench
8. Let Urethane Dry for 4-6 hours or until dry to touch and your finished!
   

   

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