1 1/4" Thick x 14" Wide x 96" Over-sized Pine (or wood of choice) (Note: If over-sized wood is not available, use 2x4's glued edge-to-edge and planed to size): One Piece for the Top and two Legs
1 1/4" x 3 1/2" x 96" Pine (use 2x4's or wood of choice): One piece for three Braces
2 " Wood Screws: 1/8 lb.
1 1/4" Kreg Screws: 1/8 lb.
3/8" Wood Plugs: 4
sandpaper 100 grit, 180 grit, (320 grit for finishing)
Satin Finish Polyurthane Varnish
Power Drill with DeWalt 9/64 Tapered Bit with Plug Cutter
Router with Round-over Bit
Sliding Compound Miter Saw
Belt Sander or 100 to 180 grit sandpaper and a block (320 grit for finish sanding)
Kreg Pocket Hole System
Sand Paper (Grit: 100 and 180)
Step One: Cut The Bench Pieces - Determine the desired size of your bench or use the dimensions provided here.
Select the planed 1 1/4" x 14" stock: Crosscut the Top and Two Leg Panels per the dimensions above
Select the 1 1/4" or 2x4 x 96" stock: Cut two pieces @ 23 1/2" with 15 degree angles as shown above for the two, Top Braces
Select the third, 1 1/4" or 2x4 x 96" stock: Add "SIX INCHES" to the Top Brace measurement and cut the Lower Brace @ 29 1/2"
Step Two: Make the two Legs - Select the two Leg Pieces; determine and mark the "Left" and the "Right"
Select the two Legs with the 15 degree cuts made on the top and bottom edges; Layout the cuts to be made per the dimensions above
Using a miter saw cut the top edges; using a Bandsaw, round the bottom, outer edges and cut out the hole in the lower edges
Using a sander, sand the Legs smooth (DO NOT sand the top or bottom edges)
Using a Router with a Round-over bit, round all edges (DO NOT router the top or bottom edges)
Using a Kreg Pocket Hole System, drill the holes along the top, interior edge, as show above
Step Three: Complete Bench Seat and Top Braces - Select the Seat and two, Top Brace Pieces
Using a Bandsaw, round the edges of the Seat
Using a Sander and Router, sand and router the Seat and the Top Braces (Note: Router only the "bottom edges" of the Braces)
Using the Kreg System, drill pocket holes along the "top and side, interior" edges of the Top Braces that will connect to the Legs and Seat
Step Four: Assemble the Bench - Select the sanded pieces
Select the two Legs and two, Top Braces; using Kreg screws and wood glue, attach the Braces to the Legs
Select Leg/Brace assembly and the Seat; Center and attach the assembly to the bottom of the Seat Piece
Select the Lower Brace and dry-fit it, center and mark where the Brace touches the Legs; Drill and countersink two holes on the exterior side, one the centerline of each of the Legs
Select the 2 1/2" wood screws and attach the Legs to the Lower Brace; Using glue and Wood Plugs, fill the holes; Sand the Plugs flush with the Leg surface
Step Five: Finish the wooden Bench - Select the completed Bench
Fill all hole and cracks with filler; conduct a final sanding of all surfaces
Sign your work
Sit back and admire your handy work