Jason Cameron - Official Website Official Website

Project 1:  Bench Seat

Materials & Tools:

• 5 – ¾˝x4x8 MDF
• 1 – 4x4x8 Douglas Fir (untreated)
• 6 – 2x6x8 Premium Grade (straight!!)
• 22 - ⅜˝x 5½˝ Thru Bolts W/ Flat Washers & Nuts
• 7s/y – Vinyl (24˝ x 30ˊ)
• 3” Dense Foam (4 - 24˝ x 96˝)
• 1 Can 3M Spray Glue
  

                    •••

• Table Saw, Miter Saw, Circular Saw & Jig Saw
• 18 & 16 Gauge Nail Guns W/ 1½˝ - 2˝ nails
• Drill W/ 1¼˝ Forstner Bit & ⅜˝x 6˝ Auger Bit
• Wood Glue & 1˝ - 3˝ Wood Screws
• Staple Gun W/ ½˝ staples
  

Cut List:

¾˝ MDF (All the #’s listed below are in inches)
Bench Frame End Panels

• 6 @ 11˝ x 20˝ (45˚ one end of each)

Inside Support Panels

• 12 @ 11 x 18½ (Square each end)

Bench Frame Front Panels

• 2 @ 11 x 48 (45˚ each end)
• 1 @ 11 x 78 (45˚ each end)
  

Bench Frame Back Panels

• 2 @ 11 x 46½ (Square each end)
• 1 @ 11 x 76½ (Square each end)
  

Bench Seat Panels

• 1 @ 20¼ x 78½
• 2 @ 20¼ x 48½
  

Bench Back Rest Panels

• 1 @ 18 x 78½
• 2 @ 18 x 48½
  

2x6 – Back Rest Panel Supports

• 11 @ 26

2x6 – End Table Frames

• 8 @ 20 (45˚ both ends of each piece)
• 2 @ 17 (Square both ends of each piece)
  

4x4 – Legs

• 12 @ 7¾

 3˝ Dense Foam

• 1 @ 20¼ x 78½
• 1 @ 18 x 78½
• 2 @ 20¼ x 48½
• 2 @ 18 x 48½
  

Step by Step

Building the Bench Frames...

1. Cut all your frame pieces according to the cut list.  Re-cut the 6 bench frame end panels to match the Plan Diagram (A).  
2. Attach the end panels to the front & back panels making 3 separate frames.  Use wood glue and the 18 gauge nail gun W/ 2˝ nails to join each corner.
3. Place 3 inside support panels in the opening of each 48½˝ frame & 5 in the opening of the 78½˝ frame.  Space them evenly and nail in place using wood glue & the 18 gauge nail gun W/ 2˝ nails.
4. Attach ¾˝ x ¾˝ scrap wood nailers to the top of each support panel & the inside top edge of the end panels using wood glue & 1˝½ nails.
5. Notch the 4x4 legs (refer to diagram H) and attach them to the bottom inside corner of each bench frame using wood glue & 3˝ wood screws.
6. Cut the 11 back rest panel supports to match Diagram F on the plan.  Attach 3 supports to the back of each small frame and 5 to the back of the large frame.  Refer to diagram F for this step.
   

1. Cut all of these panels according to the cut list.  Cut, fit & glue the 3˝ foam to each of these panels using the 3M spray glue.
2. Cut the vinyl to fit each panel.  Note:  The vinyl should be cut about 10˝ - 12˝ wider & longer than the size of the panel.  This will allow the vinyl to wrap around the edges & lay flat on the back of the panel.
3.  Pull the vinyl taught and staple it to the back side of the panel all the way around.
   

Attach the Upholstered Panels to the Frames...

1. Attach the seat panels to the top of the frames by screwing from underneath through the ¾˝ x ¾˝ nailers.  Use 1¼˝ wood screws for this and pre-drill each one first.
2. Attach the back rest panels to the back supports of each frame.  Pre-drill & countersink the back edge of each support and drive 3˝ wood screws through into the back of the panels.  Two screws in each support should do the trick.
   

Build & Attach the End Table Frames...

1. Cut the table frame pieces according to the cut list.  Build the frames using wood glue and 3˝ wood screws at each corner joint.  Refer to diagram G of the plan for this step.
2. Attach each end table frame to the ends of each bench frame using 3˝ wood screws.  Keep the top of the end table frame flush to the top edge of the end panels.  Refer to the Top View of the plan for this step.
3. Cover the top of the end table frame with a custom cut slab of granite or solid surface material.  This joins the 3 bench frames together and makes it one “u” shaped couch.  
   

Finishing Touches...

Paint the bench frames and enjoy.