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Building a bench can be a fun and rewarding project. The process can be straightforward if you have the right materials and tools. With careful planning and a little creativity, anyone can create a beautiful piece of furniture for indoor or outdoor use.
This article will guide you through the key steps of building a sturdy and attractive bench. From starting with the right cuts to adding finishing touches, each part plays a role in the overall outcome. The goal is to make it enjoyable and easy to follow, so even beginners can join in and create something special.
Key Takeaways
- Start by drilling pocket holes for strong connections.
- Create angled braces for added support and stability.
- Finish with a protective coat for durability.
Preparing the Materials
Drilling Pocket Holes
Start by drilling pocket holes at both ends of the bottom shelf boards. This will help secure the bench seat boards together. Use blue pocket hole screws that are suited for outdoor use for a strong connection.
Assembling Bench Seat Boards
Next, assemble the bench seat by attaching the boards together. He pre-drills pilot holes and uses 2-inch screws, placing two screws in each board for stability. After this, he finishes with sanding, ensuring the surface is smooth before applying any stain or sealant. For outdoor use, a protective finish is recommended.
Building the Bench Ends
Cutting the Supports
To start, he drills pocket holes at both ends of the bottom shelf boards. He continues by making pocket holes in the boards for the bench seat. Using blue pocket hole screws made for outdoor use, he attaches these parts together. For the bench ends, he prepares the upper and lower horizontal supports along with a vertical support. The lower support features 45° cut ends, while the upper support has notched ends, aligned with the bottom.
To make clamping easier, he places a couple of scrap 12-inch boards on each side of the vertical support. Next, he drills two pilot holes for 2.5-inch deck screws at each end of the vertical supports. He then glues and attaches four angled braces. Angles of 54.7° are set against the vertical support, while the 35.3° angles are connected to the horizontal supports.
To achieve the 54.7° cut, he suggests making an angled cutting jig. Adjusting the arm to 9.7° allows the saw to create this specific angle safely and cleanly. The other end is then cut at a 35.3° angle.
Assembling the Vertical Support
He notches the bottom inside corner of each foot before gluing and nailing them on. Once the feet are attached, he moves on to the bottom shelf boards. To ensure correct placement, he clamps two 6.5-inch spacer blocks on. After that, the seat is placed on top, and he uses 2-inch deck screws for attachment, pre-drilling pilot holes and securing two screws in each board.
Finally, he emphasizes the importance of sanding. After a final sanding, he is left to choose a finish. He stained the bench with dark walnut and recommends applying a protective finish if it will be placed outdoors. His wife Ashley decides to use the bench as an accent piece in their home.
Adding Braces
Cutting Angled Braces
He started by drilling pocket holes in each end of the bottom shelf boards and bench seat boards. Using blue pocket hole screws meant for outdoor use, he attached these components. For the angled braces, he used a cutting jig. By adjusting the arm to 9.7 degrees, he could cut a 54.7-degree angle, which made for a clean and safe cut. After cutting one end, he repeated the process for the other piece, making sure to get both angles right.
Attaching the Braces to Supports
Next, he began attaching the angled braces. The 54.7-degree angles were fixed against the vertical supports, while the 35.3-degree angles were connected to the horizontal supports. To make it easier, he used scrap boards for clamping. He also drilled pilot holes for 2.5-inch deck screws at each end of the vertical supports. This approach ensured a sturdy assembly as he glued and nailed the braces in place.
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Final Assembly
Attaching the Feet
The feet of the bench were notched at the bottom inside corner to ensure a snug fit. They were then glued and nailed securely to the bottom of the bench frame.
Mounting the Bottom Shelf
To attach the bottom shelf boards, a couple of 6 and 1/2 inch spacer blocks were clamped in place. This ensured the correct spacing and alignment of the boards during assembly.
Placing the Seat
For the seat, it was positioned on top of the bench frame. They used 2-inch deck screws, pre-drilling pilot holes for each. Two screws were added to secure each board firmly in place. After that, a final sanding was done to smooth everything out.
Finishing Touches
Sanding the Bench
To prepare the bench for finishing, he performed a final sanding. This step is essential for achieving a smooth surface. He made sure to focus on areas where there might be rough edges from cuts and joints. A well-sanded piece will help the stain and protective finish adhere better.
Staining and Protective Finish
He chose to stain the bench with dark walnut for a rich look. Staining enhances the natural beauty of the wood. After staining, it’s important to add a protective coat if the bench will be used outside. This protective finish helps guard against weather damage and prolongs the life of the bench.