Click here for larger image

Instructions for Cutting Parts

1. Parts A - Select three of the 2x4x8s. Cut a 24" length from each one of them. Mark these 24" pieces (A) and set them aside. These are the cross members for the upper sub frame as shown on the plan.
2. Parts B - The remaining portion of the three 2x4s in Step 1 will produce the 6 bench legs. Cut each three boards into two equal lengths. Mark these six pieces (B) as shown on the plan and set them aside. The length of each leg should be approximately 35 7/8" inches. This dimension will vary by the width of the saw kerfs and the fact that the dimensions of lumber may vary slightly. Note: This will yield a finished bench top height of approximately 36 1/2". If the builder uses precut studs (92 5/8") instead of 8' 2x4s the finished bench will be approximately 3" inches lower.
3. Parts C - Select the remaining four uncut 2x4x8s. Cut an 18" length from each one of them. Mark three of the 18" pieces (C) as shown on the plan and set them aside. These will be used in the lower sub frame of the bench. The fourth 18" piece is scrap.
4. Parts D - The four remaining portions of the 2x4s from step 3 will become the side rails of the upper and lower sub frames of the bench. Mark these (D) as shown on the plans. They should be approximately 77 7/8" long.

Instruction for Assembly

1. Assemble the upper sub frame using 2 of the parts marked (D) and the 3 parts marked A. Use 2 - 3" drywall screws at each joint. The finished frame should be approximately 27" x 77 7/8".

   
   Click here for larger image

2. Assemble the lower sub frame using the other 2 of the parts marked (D) and the 3 parts marked C. Use 2 - 3" drywall screws at each joint. The finished frame should be approximately 21" x 77 7/8".

   
   Click here for larger image

3. Square the upper sub frame using a carpenter's framing square. Tack a scrap board across two of the corners to hold the sub frame square while the bench is being put together. Failure to square the frame will cause problems when the plywood top is attached.
4. Clamp one of the legs marked (B) to each inside corner of the sub frame. Stand the bench on the 4 temporary legs.
5. Use the level to check the bench. Make adjustments to the legs to allow for any irregularities in the shop floor. These adjustments may cause a slight change in the final height of the bench top.
6. When the bench top is level permanently attach the legs to the upper sub frame. Use the 3/16" drill bit to pre-drill one hole in each of the four legs. Drive a 3" lag screw into each of the pre-drilled holes. Be sure to thread a flat washer on each lag screw before installing it. The washer will keep the head of the lag screw from sinking into the sub frame. Use a ratchet or an impact driver to screw the lags through the upper sub frame and into the legs.
7. Before pre-drilling for the second lag screw in each leg, the legs must be plumbed vertically. Use a level to adjust each of the 4 legs to plumb, clamp the plumbed legs, and pre-drill the hole for the second lag screw. Thread a flat washer on the lag screw and drive it through the sub frame and into each of the 4 legs.
8. Clamp the middle legs to the upper sub frame. Pre-drill one hole in each of the middle legs using the 3/16" drill bit and install the 3" lag screw with a washer.
9. Plumb the middle legs using the level. Pre-drill the second hole in each leg and install the second 3" lag screw with a washer in each.
10. Slide the lower sub frame between the legs of bench and clamp it in place. Note: The height of the lower shelf is a builder's choice. Locate it to allow for storage both above and below the shelf.
11. Make sure the lower frame is square and level and clamp it in place.
12. Pre-drill holes with the 3/16" bit and install two lag screws with washers at each junction of the legs and the sub frame. The lag screws will go through the legs and into the sub frame.
13. Mark the plywood for the first cut. The sheet should be cut to fit the top of the upper sub frame.
14. Cut the plywood length wise into one 27" piece and one 21" piece.

    
    Click here for larger image

15. Attach the top by driving the 2" drywall screws through the plywood and into the sub frames. If appearance is a concern, attach the top from the bottom side using the same size screws.