DIY Garden Bench

 

Royal® trim board makes a perfect resting spot by any pond or outdoor space!

Let’s do this.

DIY Garden Bench
Project Location:
Time Commitment:
Skill Level:
Exterior
8+ Hours
Expert
Download How To Guide
 
What You’ll Need
 
Tools
  • Hearing Protection
  • Safety Glasses
  • Drill Bits
  • Power Miter Saw
  • Drill/Driver
  • Jig Saw
  • Table Saw or Circular Saw
  • Tape Measure
Materials
  • 2ea - 2' x 4' x 3/4' Handipanel
  • 1" x 8" x 8' Royal Trim Board
  • 1" x 2" x 8' Royal Trim Board
  • 20ea - Cortex Plug and screw fasteners
  • 2ea - 1/8" x 3/4" x 8' aluminum bar
  • PVC Glue
  • Optional - white acrylic latex paint
 
Instructions
 
STEP ONE
Cut Bench Parts.

Scale Design - Use the provided PDF of the legs to scale the image to a piece of poster board {24”x34”). This technique has been used in the industry for years, but if you’re not familiar, here a few articles/videos on how to scale a drawing: https://www.youtube.com/watch?v=jCbsTj3lzk8 https://www.woodmagazine.com/woodworkinghow-to/ layout-measuring-marking/how-to-enlarge-griddedpatterns https://www.woodworkersjournal.com/video-how-toenlarge-gridded-drawings/. 

Layout and Cut - The legs are designed to fit two per handipanel (2’X4’) as illustrated in the cut photo. For a smooth (non-wood grain) finish layout two panels with the smooth side up and one panel with the grain up. Rough cut the blanks with a jig saw and leave enough material to trim to final shape.

Sand to Shape - Sand one of the panels to the finial shape. This is only required for the initial panel.

Secure two panels - Temporally fasten two panels to allow for routing with a tracer / pattern cutting bit. This will make the master template for each leg.

Route to size - Using a flush cut bit, size the rough cut blank to the sanded finished leg blank.

Centers of lamination - These properly shaped legs will be used to complete the lamination and shape the additional parts.

Lamination - PVC glue the mating parts to both sides of the centers and clamp. Ensure the proper sides are exposed (smooth/embossed) NOTE: the PVC glue will soften the material for a number of days, so be careful around the edges to not encounter squeeze out.

Trim to size - Use the flush cut bit to trim the lamination to shape.

STEP TWO
Cut Bench Parts.

Cut Seat and Back to Size - Follow the drawing and cut the parts for the seat and back of the bench. Leave the smaller parts oversized so they can be trimmed to size during lamination process.

Cutting the Arch - Use the same technique on the arch as used in creating the legs. NOTE: link to arch layout: https://www.youtube.com/watch?v=C-y_nr-O9Sk 

Aluminum Reinforcement - Cut grooves in the seat boards to accommodate the aluminum bars. A simple pass across the blade at the proper height. You will need to use a 2-part epoxy during the assembly of the lamination to adhere the aluminum to the PVC. NOTE: the PVC glue will soften the material for a number of days, so be careful around the edges to not encounter squeeze out.

Laminate Boards - Cut a spacer block to simulate the legs and use during the laminating assembly. We used PVC and instant adhesive to eliminate the need for metal fasteners.

STEP THREE
Assembly.

Finishing the Edges - The emboss will create an uneven seam line. To cover this, use all-purpose putty. After application and allotted cure time (15 min.) sand the edges with 220 grit sand paper to provide a smooth finish. NOTE: if you’re not painting the entire project, a light coat of fusion spray paint (white) will cover and protect the filler.

Dry Fit - Clamp the seat and back to the legs for fit and mark the aluminum bar location on the legs. Dismantle the bench and cut slots in the legs for the aluminum with a jigsaw. Cut quality is not critical as it will be concealed in final assembly.

STEP FOUR
Finish it off and enjoy!

Final Assembly - For the fastening of the parts, use PVC glue and Cortex Screw and plugs. Clamp the back on to hold the legs in the proper position during seat assembly

Build Complete - After adhesive has cured the bench is ready to use.

 
 
 

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Download project plans to get started with your design.

 
 

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