Monday, February 10, 2014
Project How to build a 5 board bench
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I started by cutting the legs to rough length using my little cordless saw. I dont feel safe cutting
pieces that long on my contractor table saw.![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZGF2m2A1rapoPqSFkeHZm3bVknGgGtewkWg33P3e4lTRiHq8D1aQGAG4MiWznE-w4SL4smfWA0kQw9xYyiZ857hb8zCVDHDQLV77-yY-IyF9bqMdKC5ddLN8E6yAsOnOTI8SyxZMrFhEN/s640/01.jpg)
I then cut them to length and width on the tablesaw.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXLgTExGOU6uKQJxS4R4zxrRRCKVhbs9Y9TcU_PUK2QcdHaRmlvR2xVyrHMgjxffkZac0OfrwxTi9MwgNFtPpsIJCdXI0evBenoyMK2eaXD7ctpymhxRTzTmQ6OQVIOG1emMxM_y8R82YX/s640/03.jpg)
Here are all the pieces cut to size. There is 1 extra 1x6 in this picture because I was originally
going to put a support shelf under the seat but the legs are slightly bowed and it didnt matchup when I cut the shelf straight so I decided not to use it.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR85zrX0b6KfwY6nDnxikRAdwUOBMEPsgPX8U7h0qQt5MR6BbpRSJKjqUkl3GxmFLoqvLWhwmmWIa4erOlHQRSk4PXkV7DAhM07ZLwEIUYugVBkxxDEwuJmMQ1gugSRQvwFGBNeVS7ZaWQ/s640/04.jpg)
I used 1 of the side aprons to mark the notches on the legs.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrtQhSOW0lVSJ4ug-67TN4JFgh8TLoF9MNYCUyOvk_rdwC8VGgOwrFl-T3-B3ncVmJWBbg7Fq_Vs9UMzbCCFwX830IoBV_wLshUpAbOp52G2PlVCjpcAL4GI0QoIluJRdh2jqvqxe5BlpE/s640/05.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGwCvUfsRVh0nQp_ZXMzMS_LzpraG4ZYPocBDSgp3fG0LHeAVV0HhHoMzbNnqFU0X4EhoOOkMxUluJDviixDo9vCyQ8dBXgNcyr4ckcWzgz1Hte3tBC1nexF-Z29CBcoaRyEOGV3ml6vi7/s640/06.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihMmrKMMSvpPZZameReV41_RDyL_JoOaCNd-mqWtOtsB33FfXGNmLyddubYUfVNSekI3vXspwz8l5SN-uOc6qw9S6V6BIOe8Be8xNqwBeC1qp00qLUL5KwBYymHyqrfe4pbkafX2Vnv5Mh/s640/07.jpg)
This notch will be cut out and the side apron will rest in it.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRmA9vbZIsDnz5gAIXZA5om2Q4WPVzYngn79Bi7ivBOY94DqOwQf22Ibp028lkJjX2fdQIKAyOiVgvfn0zmjSelrv5wQTRf1DOhImjB7_d5RHoJnD0N6eOa69eJ5MWcO6-cHy1kASf2Ym8/s640/08.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiM-nmda3T0wLv4mFn1JTHiz3M3X5folYWA-ulFiXaZCR_bBMHoBFMtquRVMTNtS2WDoy4WojO3OmMxdXP0uxq-HyY6Tk0pplF7pGlQbtDD4mt0ty6O5bHsdKqQIbw5k-q9S6mIvwbWYB_K/s640/09.jpg)
I then marked in 3" on the other end of the board for the width of the bottom leg.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdy5vi3aPehZVv6d00WFTwzu2TZyGCZA3l4QLb85CYWswbhOtyyPw65U-iRlTe3ZOLklPN6eadCq5yFEm5nHMfLfvC_LJ9cKe-jtlNdpYTBt39kzT6aRc1zxUy0onQytsXgeGTbQvd890O/s640/10.5.jpg)
I marked the center of the board at 5" to drill a hole later.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTLO_dmepq6evdE365JllKl4Z2Bf0H6PBisSQzYFSZCpioFzE_ZxCoXYaaQ7Z7UqHTI7g1gpslPdTDyr7HS7k6_3PY2uTD0oQ4MORqpyKeTtUo-A4SLolmlSm5oVwppMrn_k39yKXT3CSk/s640/10.jpg)
I then glued the aprons to the top pieces.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZnspM3CLGpdv_V3tQWmZ0BfQiE9JGUuun4ZlZoz90ZeZuU8Y7GQXO0mmYI1PRBfXxBSn_kcyTpaRaM2as-mHxJAuwg8dvknhtHw1k8SufRW82oHZyxgDGi9IKlTCnl36D3Sxx5plTj-lI/s640/11.jpg)
I drilled out a 1 1/4" hole at that 5" mark. It is recommended that you drill a hole rather than just cut a "V" there so that the board doesnt split later on.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0pwC1M7pOOD3Pk5VCzPL2Jorgl60SVhAvksnNo6Hn2Z7925UTUM1GdnNL6YnxSXtBs1ck4l_XrJUeGidXKytS33_2hUu9VHnIlPCKGJRIHugQF9H6xr2VkLruAB8lOZ53RbvJk6-VrHtx/s640/12.jpg)
I then drew a line from each side of the hole down to the 3" mark that I made earlier.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUQTON9VrqsxY0yO0fNyC_5fI9CHrOAuX1EqBiYazWS49L6x59HUrQ2UimRJhnj-3Ixa0PUs0bfYYlCE5egSDj5ythpKuQD64rwAV5Onc3mwHdgmZ-cOfDzFyBH4F4SEcKmOB0o-eFmElQ/s640/13.jpg)
An d cut the shape out on the bandsaw. You could just as easily made these cuts with a jigsaw.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDDQLHEnv8pP88dqpjLw38miCQtEFcJ5MF_9rwONEtojDhvmdLW5-unE9SToHm9sFv_1gDnSv7kbM1CBZchAT4HyGWOpsouLVETmh6JJrcrz4_ktaT1sshbrKhcxuiDY7S5Ko1mJ_XFHSX/s640/14.jpg)
The legs are slightly bowed so I marked them to have the rounded side facing out.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7RPj-YAfP2up4T-5MpQaYo3QEkbMAio2EHwYQJSYfSh8uBOfYRuSUB_SXqyn82Fjo0hdewDT9xOHmSM0dN48vs76s62XvvJWm0rLqGPwlOe1tURVG4Wm1FdQpwVZCtiZhDsTDo6F4QhOp/s640/15.jpg)
I used the scrap pieces from the legs to make some blocks to glue in later.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSLYQkjR8axRvQgk6l6-dyZrVtqqCdf8QSVITwZ5vGiLjPnpLZfdVpN_3rmdg8tgsGu-eqqyPzAaw1-DnFbQMADhJ-ELz-q93mVPzW87r_agvetz1_1GLMmptPNE8jbUIPiFuJ7bJbRwmX/s640/16.jpg)
I used my little sanding wheel on the drill press to smooth the inside of the legs. I found this one at
Lowes for under $10.![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibuY_yygDgwfmRrkUYpAkSHbeI0krMMpNCCZsFinn9kiHHOLTj_BUiGVxS8qjtOu-PdUEmk-eGj7FhhOfPeBLkMjyGbU2uDuhFkAk0Ydg88wumtj-3WBc9DvJ0JZUTvLoHe6q_tL-RzCJc/s640/17.jpg)
I then rounded over all the sides not getting glued to something else.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBQpLNUhlltxyG0ZztqDY0_95ZXGShP7XaN6LYYD4ufs11gnFRypC0wQyU8HAIjfgZdLE5wJTLPAfKxKB__GSYvwdTEZuZLQCUvSrABKE6-R2_EM0blW3Ite0B51Zk9Hrb_8C9cS3k3ekI/s640/18.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7OMrJa9P1WWuiwd8ACcCRKj5J1mdiXUI-iA7r_1UUnSnXw7GIUCF1l9iaUezQ78v4K_zrJnks4hfDfHIcUkkzjxk2vGDq-aa3c1dWw0jJrc2xRJq3ygsahUpggxBazRo5ZyqIf3YWqYhp/s640/19.jpg)
I sanded everything before assembly. I also only sanded it to 120 because I am going to paint it.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFFYB7J7-sHwadK4s1nq7qSLxbKgaPnUzMHdYXJ7WsFL4VuQ4-zFAGr37TqK-Fb9_ajoLvJTXPHPy4bHDuL6OBiL6ebThBhQraPcAorcMSaxwdnhkaa8IjrPvGBEDAH9GDA1aMIQ9Z3-Jk/s640/20.jpg)
I clamped it up to see what it was going to look like.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3Xn69yQYzJxO-k-lvIzMGDHBz67AwMDxojPnMZsnYlR2osqDg847-6sKozguK_F1cIH0Y-YJ-lTDNWTaSRhigFAN9xEOorRAPM7mbGms6TD5IkSLmk_CNAx4DvT_DSAPWP0rmk5HyIvLW/s640/21.jpg)
I used a scrap piece of 2x4 as a spacer for the ends.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-DfKyLjdlyPBMeQsDeohyphenhyphenj43gFXV5zzeUqac0mGIaM0_NWmxndLk38rRUC8Q-5zruCHmOSoMzaCPUrEoN7UBXL-9oawEsQABEBJDe1ttXCsRUR-GO2yf4836ExLivr1wAzBh2kVjb95rc/s640/22.jpg)
I glued the legs to the top/apron pieces and then made sure that they were square before clamping them up.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimQqbo8c_pVJemNNA2kb5psArC8oXBPGWOObF1TzIarpGZZdAvVln_Gq78n9e0O71lOsXVhtqurPIQyWRzdiRK8-nCj76KX0r3QSxjRwV436ElvTkil7AEks3mBYC_ahTz8hfGg4DM3bWw/s640/23.jpg)
Here are those block that I cut out earlier.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoyJZTY-RL0U5XjqNYg4C0osA5djK4rBfU8N4ozFViuexwQYLZaykuCH23eEPTiDpaO2NooVN8PN_2WlBSNJzu4F9wbWTdWYNWta21ORcOaW4lvbAKRS0EbmhYEL1aqQJAw5OHk2XV3G7d/s640/24.jpg)
I took it out back and spray painted it flat black.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH1dE3sS6YwC2wbQIMnz94F3N54XjCnzFOint2VU2H7tfaTSbhCgDTe1OnDoR1VNNywfwFiTk0x9ZOnfIBe_OfHT8XMVU8j8jF2QG9csAt_lGjIshqE22Q6ySYUSMZGt6KAzq7AMpBQA4d/s640/25.5.jpg)
I sanded the whole thing with 220 to smooth it out and also gave it some distressing to make it
look a little older. Im not a big fan of over distressed projects so I tried to keep a semi-light touch.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3AhT2kylQ7wmx6HofwmA_NmIfMDLSTNGI0BZGdKR0to4lvGfUiCNZjWFBtPPOLDFPvpopqJL4CneejRxdiFGJND5zDlDyHDgC-G4Ve0FkO3U8asHBNn39stjBby0lV9PYOc0FRarAHBGv/s640/26.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfzOboYINz_HGlkWOIrynA6qtIMYyBC2LNBw86zUFIY2cp8gp4wliYjCMBGaG_BvS61HggkWcmIOur0FqnzxqT-ci15EYZypNkpJad_KJhpIKBgSzEXhiib_OAmAGkCnPnYKdnOvtiCxm9/s640/27.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQetkf9ZRC7EaN57nYSX4syZl4iL-jUBtstb4-X7YfseXnMlVEiywCHFLVBJyEQN-izIWBk2JD40mUso83aYiyI1NBcyInc2r_GFvGwMK4kgfyNrbCoW6RiGBj7rok7mHtwEqsGH1t5wDg/s640/28.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTeuMrU59CznTyDUGfIe8S_PH5gY69KzscUGJxOZY5IiSNmUFMQxD_64AGb_ZPEb2UlIMW0NKaewg899hIjNVQfcILgQOy6f4h7JZMu-RcP5TEsFkeDZDdUtO8aTEYIcHIJYxCYpycJPgz/s640/29.jpg)
This was my first time using satin poly. Ive only used gloss up to this point.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyV8dC6KRbCnNEqqsvBzY296EbnNxdVX19QmmrjPs70kkxQDheHKEs3p4p_hehDY4yw0vqHuo8LYPW5KzdBulBHEyJNflYCkw85rtzS2P5JwAbFHWM_huCo_s-Lg_r38aJI5RKCuiDfS9q/s640/30.jpg)
I ended up putting 4 coats on the top and aprons and 3 coats on everything else including the underneath. I also put some felt feet on it but forgot to take pictures.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsT771EJsMufTNugjffkwJBWxz_BmDa40JK8691mEydt8tT127a4RG4TGwUUSDP3A8RIZhws-NVQzPJllxQA8_sOCvvy2HyNbNs8mmL2_Mla_Z5c_d0ovuEsOM2pJ0vnzxzzOBEdbQK85X/s640/32.jpg)
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