TOOLS

Saw, hammer, spanners, measuring tap, mitre square, pencil, electric drill kit and drill bits, plane or disc sander and sanding discs, 6" G-clamps

A bevel gauge would be handy or a simple template as in step 9 could be made from thick cardboard.

HOW TO

1. Cut two table top rails (B) each. 750mm long from the 90x45 material.
2. Cut table top cross bar (C). 900mm long from the 90 x 45mm materials.


3. Mark out each table top rail to pattern using rule/tape and template. Trim, round ends or mitre cut as shown.




4. Cut two seat rails (D) each1.5m. Mark out seat rails as below using rule/tape and template. Trip ends, round or mitre cut as shown.
5. Assemble two end frames to pattern shown using nails or clamps at each joint to temporarily hold pieces in place. Drill holes where indicated and insert 10mm bolts and lightly tighten nuts.
6. Cut two seat planks 1.5m long and mark out to pattern below.


7. Screw fix, using couter-sunk screws, on seat plank to each end of the seat rails fixing outer plank so that it projects about 10-15mm beyond end of rail.




8. Mark two bracing pieces (F) to pattern shown below on the 75mm material. Cut out material shown shaded.





9. Line up brace on seat rail and at 45 degrees to table top crossbar (one brace each side of top crossbar) mark off brace on bar and cut to fit flush with top edge of top bar. Screw fix brace, checking that angle made with bar is 45 degrees and the whole frame is "squared up."
   
   
   
   
   










10. Round off using sander, or bevel using plane, all edges and ends so as to reduce hazard to users, and to provide better pre-paint or pre-stain adhesion all over accessible timber.



11. Mark and cut remaining 12 planks for table top (8) and seats (4) to the same pattern used in step 10. Drill holes for screws including counter-sinking. Round-off all edges.


12. Screw fix to seat rails and table top rail allowing equal spacing between seat planks of about 6mm but adjusting table planks spacing as required.




13. Tighten all bolts. nuts and screws then apply two coats of stain or other timber protection as required.



14. Re-adjust screws and bolts every 6 months.

Safety >>

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