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First
build the two armrests. |
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Trim
the front end of each 4x6 armrest at a 45-degree
angle, beginning one and one half inches down
from the top. Make a 3 1/2-inch square notch in
the inside back of each armrest where it will
wrap the rear leg, and finish with a 45-degree
bevel cut. |
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Using
4-inch screws, attach the armrests to the 4x4
rear legs, 24 inches up from the bottom. Attach
armrests to the front legs by driving two screws
through the armrest and into the top of the leg. |
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Trim
the 2x4 main braces down to lengths of 5' 9"
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...
and attach them to the inside front and rear
legs, 11" from the bottom. |
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The
curved seat supports are made up of 2x4 lumber
sandwiching either the 4x4 rear legs-in the case
of the end seat supports-or the single 2x4
backrest support-in the case of the center seat
supports. |
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To
shape the curve, make a template for a 36-inch
radius cut. Mark the cut to start 3 inches in
from the front, and use a jigsaw to cut the
radius and finish the seat supports with a
45-degree bevel cut to match the armrests. Note
that the end and center seat supports differ
slightly in length and attachments. |
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Trim
the four 2x4 end seat supports to 25-1/2".
Attach the inside seat supports to the rear and
front legs so they rest on the top edge of the
2x4 main brace. Attach the outside seat supports
level with the inside ones. |
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Trim
the two center seat supports to 22 inches. Using
a scrap piece of 2x4 as a temporary spacer for
the backrest, attach these seat supports across
the main braces flush with the back edge of the
rear brace. Use two 3-inch screws for each joint,
angled from below and inside. Remove the spacers. |
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For
the backrest supports, trim the 2x4 supports to a
10-degree angle at the top edge. The two end
backrest supports start at the top of the 4x4
rear leg and trim to rest on top of the seat
supports. The center backrest trims flush to the
bottom edges of the two center seat supports. |
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Attach
the end backrest supports to the inside of the
4x4 rear leg with two screws. The bottom should
fit snugly to the top of the seat supports and
can be secured with screws driven at an angle
from below. The top rail should be installed
before trimming and attaching the center
backrest. |
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Now
you will attach the 2x4 top rail to the rear legs
with three deck screws at each end. |
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Measure
and trim the center backrest. Install the
backrest between the seat supports and place it
flush to the underside of the top rail. Secure it
with screws. |
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For
the backrest rail, trim one 2x2 backrest rail to
fit tightly between the armrests. |
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Trim
the other 2x2 and 2x4 seat and backrest rails to
6' so that it goes across the entire length of
the bench. |
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Install
the front seat rail so that it overlaps the seat
support by 1/2-inch, and attach it with two deck
screws at each joint. |
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Attach
the rear seat rail to each support with two deck
screws. Adjust the spacing of the remaining seat
rails before attaching. |
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Space
the backrest rails equally, and attach to
supports with a single screw at each 2x2, and two
screws at each 2x4. |
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Sand
with medium grade sandpaper and apply the finish
of your choice. |