Materials:
one 4' x 8' birch plywood
two 6' x 1" x 4" aspen boards
two 8' x 2" x 4" construction grade for top of bench
two 8' x 2" x 4" construction grade for cross braces and end boards
circular saw
jig saw
tape measure
speed square
chisel
pencil
hammer
drill with screw bits
drill bits
six 2-1/2" L-brackets
finish nails
Steps:
1. Begin by establishing the length of the bench (the materials listed will produce one 36" long). To prepare the top, cut two 2x4s to length using a circular saw. To add strength, cut notches into the long 2x4s so that two cross brace 2x4s can be attached to them. Place the long 2x4s together and clamp onto a workbench. Measure in 13 inches from each end and make a pencil mark. Measure over an additional 3-1/2" and make another mark. Using a speed square, draw lines across both boards to be used as your cutting marks. Using the circular saw with the blade set for 1-1/2", cut out the notch using the speed square as your saw guide. You want to nibble away the wood by making several cuts across the board. After you have finished cutting, use the chisel to remove any excess lumber . For the braces, cut the remaining 2x4s into four equal lengths measuring 24 inches each (two will be used for the end boards and the other two as centerboards that will fit within the notches). Attach the two end boards so that they match the two side boards standing upright and lay the two center braces flat across the sides. This completes the support portion of the top.
2. Cut four side pieces out of birch plywood measuring 24" x 24" using a circular saw and a guide edge to get a square cut. The side panels attach to the top support system using wood glue and drywall screws. Attach the inside leg panels to the top support 2x4s on the inside. You will have to notch out the panel where it butts up against the 2x4 so that the side will fit up into the support braces. Measure the 2x4 and transfer your measurements to the plywood panel, and then cut out the notch using a jigsaw. The outside panels attach to the support system flush to the top of the 2x4s. For the bottom of the two side panels, cut a 2x4 to length, attach between the two side panels (at the foot). This provides the basic structure of the legs and the edges of the plywood will be hidden by the front facing of aspen.
3. Cut a piece of birch plywood that measures the exact dimension of the top support assembly. (It should measure 24" x 36", if you used the featured project's measurements). Again, use a circular saw with a long guide edge to give a square edge. Attach the panel to the top from underneath using L-brackets and screws. You could attach from the top using finish nails, but Matt and Shari were concerned that the nails could eventually pop up and hurt a small child, so they opted for mounting underneath. Use six L-brackets (one in each corner and two placed at the center) to make sure the top is fastened securely. To finish off the bench, use the aspen 1x4 to trim out the front. Cut the lengths using a miter saw and attach using wood glue and finish nails. Set the nails with a nail set and spackle. Prime the assembly and paint with a color of your choice using a latex satin paint. For further protection, apply several coats of polyurethane .
