To build a bench, create the shoulders, add spacer blocks and the legs, drill bore holes, and glue the parts together. You need five pieces of 2-by-4-by-8-feet lumber, a piece of 1-by-4-by-4-feet lumber, and a piece of 4-by-4-by-8-feet wood to complete this project.
- Cut the shoulders
Cut nine seat boards, four legs and 12 spacers with a crosscut guide and circular saw. Cut the tenon at the top of each leg using a table saw. Make shoulder cuts at the opposite ends of the legs. Apply a clamp to the rip fence, and adjust the cutting blade 3 1/2 inches from the stop block. Set the blade to 3/8 inch to make the cuts.
- Cut more of the shoulders
Turn the leg over to make the second shoulder cut, and do the same for the remaining three legs. Set the fence aside, and remove the tenon bulk as you hold the leg against the miter gauge. Use a chisel to pare away wood slivers.
- Apply spacer blocks
Use blocks that are 3/4 inches thick and 3 1/2 square inches as spacers. Nail these blocks to six 2-by-4 seat boards. Glue a block 3 1/2 inches from the outer ends using 1 1/2-inch 4d galvanized finishing nails and polyurethane glue.
- Add the legs
Use 1 5/8-inch galvanized decking screws and glue to install the legs on the seat boards.
- Bore the holes
Drill 7/16-inch holes through the spacer block and board to make rod holes at each end of the seat board.
- Clamp the pieces
Clamp and glue the parts. Cut the rods to a length of 19 inches with a hacksaw. Place washers and nuts on the rod ends with a 9/16-inch socket.