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Cut
the 7 seat slats to 52" lengths. The top
slat will be thicker than the others, so you'll
cut this one from a 2X4. Cut the remaining slats
from 1X6 stock. All of the slats will to cut to
2-1/2" widths. |
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Next,
position the four pre-shaped sides to accommodate
the 52" slats. Install the thicker top seat
slat first into the slots in the sides, using
glue and 3" deck screws. Only use one screw
per joint, and countersink them flush with the
surface. |
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Now
drop the remaining slats into position. After
spacing by eye, install the slats using
1-1/2" deck screws. But don't attach the
template-cut rear slat yet. |
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Cut
four 13-3/4" long uprights from the 2X4
stock and attach them to the bottom back brace
already cut from your template. One upright
should be placed at either end of the brace, with
the space of 15-1/2" between each upright
and its mate. Install with glue and 3"
screws. |
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Cut
the four legs to 21-3/4" lengths, then, with
the seat surface elevated onto saw horses, clamp
the legs into position with C clamps. Since you
will have traced the leg outlines from the
template onto the outer surface of the two side
pieces, use those markings to show where the legs
should be placed.
Stand the clamped assembly onto the floor to make
sure that legs are vertical and the seat doesn't
rock. When ready, unclamp the legs one at a time
and apply glue and 3" screws from
underneath. |
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Cut
two trestle supports from 4 1/4" long 2X4
sections, and a trestle top from a 13 3/4"
section. Fasten the trestle top over its supports
with glue and screws. Then center the trestle on
the top seat slat, and fasten it with glue and
screws driven in from underneath. |
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Cut
two angle blocks from 3 1/2" lengths of 2X4.
Shape them as you wish, and install them at the
tops of the front legs with glue and screws. |
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Install
the completed back assembly into the angled slots
at the back of the completed seat assembly. Use
glue, and 3" screws driven into the rear
legs. |
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Cut
a 15" length of 2X4 for the rear table
support. For positioning, place a straight piece
of wood across the tops of the two rear legs, and
install the rear table support at the height of
the straightedge and parallel to the floor.
Secure it against the two inside sections of
uprights with glue and 3" screws. |
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Make
a ripping jig for cutting the tapered back slats
on your table saw. The jig should be cut from a
straight piece of scrap stock 28 to 30" long
and at least 3 1/2" wide. Cut out the
opening exactly as shown. |
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Form
your back slats from seven 1X6s cut to 3
5/8" X 24" dimensions. Then set your
table saw fence to the width of the jig, insert
each back slat piece into the jig to rip it into
two tapered slats. When done, you should have 14
identical slats. Round them over slightly. |
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Using
the 14 tapered slats, transfer these curved
profiles to the tops, and cut with a jigsaw or
bandsaw. |
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Round
over the outer edges of the template-formed arms
and the fronts of the table slats with a router.
Then space them evenly and fasten them down with
1-1/2" screws, which should be countersunk.
Each table slat gets two screws, lined up
visually, into the support assembly. Each arm
gets one screw into the front and back leg, and
one into the angle block. |
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Next,
install the back slats, starting with each center
slat. Then install the remaining slats in
half-circle patterns, using 1-1/2" screws
into the top back braces, leaving about a
1/4" gap between slats. Then install the
rear seat slat with screws. |