BUILD
THE BASE
1. Cut the leg halves (A),
cleats (B) and trestle (D) to length. Sandwich
one leg half between two cleats so the cleats are
flush with the top and the outside edge of the
leg half. Then join the parts by driving four 1
1/2" deck screws through each cleat and into
the leg half. Assemble two more cleats with a leg
half in the same fashion.
2. Stand the two assemblies on
their sides, with the open ends of the cleats
pointing upward. Arrange the assemblies so they
are roughly 4' apart. Set the trestle onto the
inner edges of the leg halves, pressed flush
against the bottoms of the cleats. Adjust the
position of the assemblies so the trestle
overhangs the leg half by 1 1/2" at each
end. Fasten the trestle to each leg half with
glue and 2 1/2" deck screws (photo A).

Make sure the
trestle is positioned correctly against
the cleats, and attach it to the leg. |
|

Attach the
remaining leg half to the cleats on both
ends to complete the leg assembly. |
3.
Attach another pair of cleats to each leg half
directly below the first pair, positioned so each
cleat is snug against the bottom of the trestle.
4. Slide the other leg half
between the cleats, keeping the top edge flush
with the upper cleats. Join the leg halves with
the cleats using glue and 2 1/2" deck screws
(photo B).
5. Cut the braces (C) to length.
Fasten one brace to the inner top cleat on each
leg assembly, so the tops are flush (photo C).
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Attach the outer
brace for the seat slats directly to the
inside faces of the cleats. |
MAKE
THE APRONS
1. Cut the aprons (E) to length.
2. Lay out the arch onto one
apron, starting 3" from each end. The peak
of the arch, located over the midpoint of the
apron, should be 1 1/2" up from the bottom
edge.
3. Draw a smooth, even arch by
driving a casing nail at the peak of the arch and
one at each of the starting points. Slip a
flexible ruler behind the nails at the starting
points and in front of the nail at the peak to
create a smooth arch. Then, trace along the
inside of the ruler to make a cutting line (photo
D).
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Use a flexible
ruler pinned between casing nails to
trace a smooth arch onto the aprons. |
4.
Cut along the line with a jig saw and sand the
cut smooth.
5. Trace the profile of the arch
onto the other apron and make and sand the cut.
6. Cut the slats (F) to length.
Attach a slat to the top, inside edge of each
apron with glue and deck screws (photo E).
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Attach a 2 × 2
slat to the top, inside edge of each
apron, using 2 1/2" deck screws and
glue. |
INSTALL
THE APRONS AND SLATS
1. Apply glue at each end on the
bottom sides of the attached slats. Flip the leg
and trestle assembly and position it flush with
the aprons so that it rests on the glue on the
bottoms of the two slats. The aprons should
extend 1 1/2" beyond the legs at each end of
the bench. Drive 2 1/2" deck screws through
the braces and into both slats.
2. Position the middle brace (C)
between the aprons, centered end to end on the
project. Fasten it to the two side slats with
deck screws.
3. Position the six remaining
slats on the braces, using 1/2"-thick
spacers to create equal gaps between them. Attach
the slats with glue and drive 2 1/2" deck
screws up through the braces and into each slat
(photo F).
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Attach the seat
slats with glue and 2 1/2" deck
screws. Insert 1/2"-thick spacers to
set gaps between the slats. |
APPLY
FINISHING TOUCHES
Sand the slats smooth with progressively finer
sandpaper. Wipe away the sanding residue with a
rag dipped in mineral spirits. Let the bench dry.
Apply a finish of your choice a clear wood sealer
protects the cedar without altering the color.
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