COST:
Total cost without optional wood glue is $51.66; with wood glue is $54.63. These are based on market pricing in Atlanta, GA and do not include tax.
SKILL LEVEL:
Intermediate
TOOLS USED:
Circular Saw, Drill, Carpenter’s Square, Measuring tape, Pencil
TIME TO COMPLETE:
45 minutes to an hour
MATERIALS:
(2) Large Crates & Pallet Wood Crates (2 at $11.97ea = $23.94, 1000051893)
(1) 1”x12”x8’ Common or Pine Board ($18.35, 458538 Common Board; FYI – Pine Board in this size is only $9.96, sku 1000019784, but is not available in all stores in Atlanta, so unsure availability nationwide.)
(1) 1”x4”x6’ Common Board ($3.47, 914673)
(16) #10 x 1-1/4” Wood Screws (2pks at @$1.18ea = $2.36, 378312)
(16) #8 x ¾” Wood Screws (2pks at @$1.18ea = $2.36, 284683)
(2) #8 x 2” Wood Screws ($1.18 per pack, 382495)
(optional) Wood Glue (8oz $2.97; 676828)
(optional) Paint or Stain and accessories for application
CUT LIST (see Cut Diagram):
(4) 17.25”L x 3.5”W from the 1”x 4”x 6’ board (legs)
(1) 36”L x 11.5”W from the 1”x 12”x 8’ board (bottom board)
(1) 37.5”L x 11.5”W from the 1”x 12”x 8’ board (top board)
(1) 9.5”L x 4”W from the 1”x 12” x 8’ board (support)
MEASURE AND MAKE CUTS ON CUT LIST
The short and sweet version: Measure, mark and cut the two boards according to the cut diagram. TIP: From the 1”x 12”x 8’ board, it’s easiest to cut out the top and bottom boards prior to cutting the support piece.
The longer version: Step 1: On the 1”x 4”x 6’ board, measure and mark 4 sections of the board at 17.25” each for the legs (see diagram). Set aside. Step 2: On the 1” x 12” x 8’ board, measure and mark one section of the board at 37.5” x 11.5” for the top board, one section at 36” x 11.5” for the bottom board, and one piece at 9.5” x 4” for the support (see diagram). Step 3: Use a circular saw to make the cuts at the measured marks for the 4 legs, top board, bottom board, and support piece. TIP: It’s easiest to cut out the top and bottom boards prior to cutting the support piece.
PAINT OR STAIN (optional)
Paint or stain all wood sections and the two large crates prior to assembly
INSTALL MIDDLE SUPPORT
Pre-drill two holes at the 18” center of the bottom board, one 3” from the edge and the next one 3” from the first.
Use a bead of wood glue (optional) along the 9.5”L edge of the support piece and align pre-drilled holes in the bottom board on top of the support piece, ensuring that the end of the support piece is flush with the edge of the bottom board. TIP: Push the 2” wood screws through the pre-drilled holes, align the 9.5”L edge of the support piece flush with the edge of the bottom board and centered over the two screws, and push the support piece down onto the screws to make an indention mark into the support piece. Drill a ¼” deep starter hole in the support piece where the indention marks are to help as guides when installing the support piece beneath the bottom board.
Drill 2” wood screws through the pre-drilled holes in the bottom board and into the support piece aligned below.
ASSEMBLE BENCH
TIP: Pre-drilling holes in the crate slats will help keep the wood slats from splitting.
Turn the two large crates slat side down and attach them side by side in the center using 1 ¼” wood screws in each of the four corners.
Align back of crates with the edge of the bottom board and use a ¾” wood screw in the bottom corners of each crate to attach the crates to the bottom board.
Attach legs to the outside of the bench ends with 1-1/4” wood screws in each of the inside crate corners. Use two legs on each side of the bench and ensure legs are flush with the left and right edges of the crate ends.
Place top board on top of crates and attach from inside of the crate using ¾” wood screws in each corner.