How We Built An Outdoor Bench

This year we had to buy new outdoor furniture for our screened in sunroom. The previous set lasted about 12 years but alas, the sun and elements did a number on them. I was sad to see them go they were so comfortable, but it was time.

This spring we bought fewer pieces than we had before and it was looking bare so we I made the executive decision that we Jim would build a bench for extra seating.

After a quick look through the lumber out by the sawmill, I grabbed two 2 x 4s and a random 3 x 3 inch board that were cut last year. Perfect since I plan to stain the bench, so the drier the wood the better.

Now on to the build…

We wanted the bench, when complete, to be about 17 – 19 inches high including the cushion, which is about 4 inches thick. That means when the wooden part of the bench is built it should stand about 14 inches tall.

These are all the pieces cut out.

First we attached the legs to the long side of the bench. Jim predrilled holes for the screws.

Here are both long sides finished.

Next up we added the two end pieces the same way…

…and the middle piece which needed some persuasion.

Here it is without the top boards.

We used one inch thick boards for the top not wanting to add too much to the height. The holes got predrilled for these screws as well.

Pretty much as soon as Jim finished the build I got to work with the stain. When it goes on it is sort of a milky purple color making a person second guess the situation but… trust the process. It dries walnut brown. Did a light sanding and a second coat of stain.

With that part of the bench complete, it was time to work on the cushion. Not wanting to complicate the cushion I landed on cutting out a piece of thin plywood to the size needed.

Then using the foam from the previous cushions, I cut 2 pieces to make up the bench cushion using a kitchen knife. An electric carving knife would make the job 10 times easier but…no electric knife in my tickle trunk.

Here are the previous cushions.

Measured and marked for cutting.

The only thing I had to buy for this bench was the spray adhesive for attaching the foam pieces together to make one, and also to attach the foam to the plywood. Worked perfectly.

With that step done I got the batting laid out and placed the foam side on the batting. I just used the same spray adhesive to stick the batting to the plywood. Cutting excess batting off the corners. Just used the batting that was on the cushions from the start.

Back in the house, I laid the material on the floor upside down and placed the foam and plywood on the material. I’ve been hoarding saving this material for 10 years ever since I made fabric shades for the glass ceiling panels in the sunroom. Never thought I would actually have a use for it.

For this part, I recruited Jim’s help getting everything tight and stapled. I did some of the staples but was afraid I would swing hard and staple through my fingers.

Next up will be power washing the deck and staining the deck boards grey but until then here is the bench all finished.

And so you can see it with the shades…

Well that didn’t take too long, just needed to find the time to get started. We’re all ready for long sunny hot days to sit and enjoy. (After the deck is freshly stained). Always something to do.

Later.

Update. Deck is stained. On to the next project.