Bench + Back

Mark, label and cut lumber in order of BB-1 to BB-7 to the lengths in the cut list.

Check each piece of lumber for imperfections such as cracks, warping or uneven milling, and discard those portions of lumber.

• Label each piece of lumber as you measure and cut it.
• Keep a separate pile of lumber for each part, BB-1 to BB-7.
• Lightly sanding the cut edges removes splinters and helps with assembly.
• Building more than one bench? A stop block on your miter saw keeps every piece the same length.

Place two BB-3 pieces on a flat surface. Place two BB-5 pieces on the right side of the BB-3 pieces, aligning the edges as shown in the image. Repeat to build a second, matching frame.

• Use a carpenter's square to check each corner forms a right angle — if it's far off, re-check your board lengths.
• Building a 90-degree jig will dramatically help with assembly of this and the next step.

Place four BB-6 pieces and one BB-4 piece on top of each frame, as shown, leaving a 1.5" gap between the two BB-6 pieces (use a spare 2x4 on end as a spacer). Use the pre-drilling guide at the end of the packet to pre-drill your screw holes, then secure the lumber with an impact driver and 30 2.5" self-driving exterior wood screws.

Place one BB-4 piece flush to the BB-5 piece below it, with two BB-7 pieces at right angles next to it, as shown — again using the 2x4 spacer for a 1.5" gap — then secure with 14 more 2.5" screws.

Repeat on the other leg, then stand both legs up for the next step.

Place three BB-1 pieces in the slots at the base and sides of the two frames built in step 3, as shown.

Secure the BB-1 lumber on both the left and right sides into the frame pieces with an impact driver and 12 2.5" self-driving exterior wood screws total — 6 screws per side.

• Check the side stays at 90 degrees with a carpenter's square.

Place three BB-1 pieces on top of the frame built in step 4, aligning all edges and leaving an equal 1" gap between pieces.

Secure the BB-1 lumber with an impact driver and 12 2.5" self-driving exterior wood screws. These screws will need to be driven in at a slight angle.

Place the two backrest brackets on either side of the BB-1 lumber, 5" inward from the ends, as shown.

Mark and pre-drill holes straight through the BB-1 lumber to align with the brackets, then secure the backrest brackets into the bottom of the BB-1 pieces with a socket wrench and four 1/4" x 2-1/2" exterior carriage bolts, nuts and washers.

• Tilting the bench over onto its front side makes this step easier.

Place three BB-2 pieces on top of the backrest brackets secured in step 6. Start with the top piece, set 1/2" above the top of the bracket, then leave a 1/4" gap between each piece below it, keeping all edges aligned.

Secure the BB-2 lumber into the backrest brackets with a socket wrench and six 1/4" x 1-1/4" lag screws.

Lightly sand the rough edges of the bench + back.

• Use your carpenter's square as a spacer for the gaps.
• Use a 1/4" drill bit to pre-drill shallow starter holes for the lag screws — be careful not to drill all the way through the BB-6 lumber below.

Cut out the pre-drilling hole guide along the dotted lines. When drilling, align the edge of the template with the outside edge of the lumber before pre-drilling.

Not all holes are used — not all patterns use the template. Use the assembly steps above for your hole guide. Keep all holes about a thumb's width from the edge (about 1"), even holes that don't use this template.