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PROJECT PLAN #SU12

Garden Bench Included in the plans: n Scale drawings n Component templates n Detailed cutlist n SketchUp drawing

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There’s nothing quite as nice as sitting outside on a breezy evening and enjoying a quiet and relaxed moment in the setting sun. Of course, you need somewhere to sit. That’s where this garden bench comes in. Its subtle curves not only add beauty but, in the case of the seat, comfort as well. Construction is straightforward since all the shaping happens after the joinery is cut. The bench features sturdy mortise-and-tenon joinery. The mortises are quick to cut using a router, a collection of hand-tool jigs, and a bearing-guided bit.

It’s made from sipo, a tropical hardwood and mahogany relative that can stand up to the seasons, even without a finish.

Size: 21-5/16 in. deep by 52 in. wide by 33 in. tall

63 South Main Street Newtown, CT 06470 (203) 426-8171

To purchase additional plans, visit www.finewoodworking.com/planstore Taunton Product # 065115

on the side and middle rails at the tablesaw with a dado head cutter. Use handsaws to cut the tenons on the front and back rails, and on the back slats. After the tenons fit their mortises, notch the tenons of the front, back, and side rails so that they don’t interfere with one another in the mortises.

Cut and smooth the curves Make templates for all of the curves Start by rough-milling all of the parts and setting them aside for a day or two. While they’re acclimating to the shop, make templates of all the curved parts on the bench. Use high-quality plywood and take your time. You want smooth, clean curves. After laying out the curves, cut them at the bandsaw. Then refine and smooth them with files and sandpaper. Set the templates aside and mill all of the parts, except the seat slats, to their final dimensions. The seat slats are cut to final width and length after the base is assembled.

Cut the mortise-andtenon joints There are a lot of mortises. A router and a few jigs to guide it will allow you to cut them accurately and in short order. When cutting the slots in the jigs, make sure to take into account the offset of the bushing you’ll use in the router’s baseplate. Make the jigs and rout the mortises. After the mortises are routed, cut the tenons of the rails and back slats. Cut the tenons

Now it’s time to shape all of the parts, except the arms. Use the profile templates to mark the profiles on the parts, and then cut them at the bandsaw. Cut on the waste side of the line and then use a rasp to work down to the line. The last bit of shaping is to rout the four relief squares in the top back slat. Use a router and jig to remove most of the waste. Then use the jig as a chisel guide to square up the corners.

Make and fit arms Dry-assemble the base and get to work on the arms.

Mark the arm profile on the blanks and cut them out at the bandsaw. Smooth them with a rasp followed by sandpaper. All the surface prep should be done before fitting the arms to the base, because any sanding done afterward could make for a sloppy fit.

To fit the arms, start with the notch at the back.

Mark its location directly from the bench. Cut out the notch and clean up the saw marks. Put the arm back on the bench and mark the location of the mortise at the front of the leg. Drill out the waste and square up the mortise. Mark the arm’s curve on the shoulder at the top of the front leg. Shape the shoulder and test the arm’s fit.

When everything is snug, glue up the base.

Assemble the base Before gluing up the base, sand all of the parts, including the seat slats. Begin the assembly by gluing up either end. Let the glue dry, and then glue in the front and back rails, and the back slats. The one trick with the rails is that you must glue the middle rail into the front and back rails before gluing them into the leg mortises. A second pair of hands is a big help here.

Clamp up the base and let it dry overnight.

Attach the seat slats and arms The seat slats sit on a cleat attached to the inside of each of the side rails. Shape and screw the cleats in place once the base is dried. Measure the opening for the seat slats, then rip the slats to width and cut them to length. Round the edges of the slats at the router table and prepare the surface of the boards. Then, screw down the slats down starting at the back. Put two screws in each slat and one in the middle rail.

Then plug the screw holes with square pegs. Make sure that face grain faces up. After the glue has dried, cut off the pegs and plane them flush.

Finally, attach the arms. Put glue on the mortiseand-tenon joint and set the arm in place. Pre-drill the back of the arm for a screw and then drive the screw home. Plug the hole just as you did on the seat slats.

Outdoor Bench by Matt Kenney

Outdoor Bench 07/27/2009, Page 1

Orthographic View

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Exploded View

Outdoor Bench 07/27/2009, Page 3

Back Leg

Front View

Side View Outdoor Bench 07/27/2009, Page 4

Front Leg

Both Front and Back Legs are 1 1/4-in. square above the 10 1/2-in. dimension. The curve starts at this point.

Outdoor Bench 07/27/2009, Page 5

Front View

Side View

Side Rail

Front View Orthographic Outdoor Bench 07/27/2009, Page 6

Front/Back Rail

X-ray view of front leg joint

Outdoor Bench 07/27/2009, Page 7

Arm

Side View Orthographic View

Outdoor Bench 07/27/2009, Page 8

Back Pieces

Tenon details

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Cleats

Outdoor Bench 07/27/2009, Page 10

Seat Slats

Plugs for the screw holes are slightly chamfered at the corners before they are pounded in.

Outdoor Bench 07/27/2009, Page 11

Seat Slat Arrangement

Note on sizes.

Seat slats are 5/8-in. thick Legs are 1 3/4-in. thick to start Arms are 1-in. thick Everything else is 7/8-in. thick

Outdoor Bench 07/27/2009, Page 12

Leg Mortise Seat Slat Jig Arrangement

Notes: Leg mortises are cut when leg is in blank.

Fence is removeable All 3 mortise guide slots are 3 1/4-in by 5/8-in.

Guide bearing 5/8-in. outside diameter. 3/8-in. dia. spiral bit

Fence registers leg blank on jig

Outdoor Bench 07/27/2009, Page 13

Middle Rail Seat Slat Mortise Jig Arrangement

Note: Guide bearing 5/8-in. outside diameter. 3/8-in. dia. spiral bit

Outdoor Bench 07/27/2009, Page 14

Leg Seat Slat Side Rail Mortise Arrangement Jig

Note: Guide bearing 5/8-in. outside diameter. 3/8-in. dia. spiral bit

Outdoor Bench 07/27/2009, Page 15

Leg Seat Slat Front/Back Rail Arrangement Mortise Jig

Note: Guide bearing 5/8-in. outside diameter. 3/8-in. dia. spiral bit

Outdoor Bench 07/27/2009, Page 16

Square Seat Reliefs Slat Jig Arrangement

Outdoor Bench 07/27/2009, Page 17

Front View Back Leg

Side View Back Leg

Front/ Back Rail

Upper Back Piece

Outdoor Bench 07/27/2009, Page 1

Front Leg, Front View

Front Leg, Side View

Cleat Side Rail

Middle Rail

Arm

Outdoor Bench 07/27/2009, Page 2