CUT THE PLYWOOD PARTS.

1. Cut the following parts with a circular saw and straightedge: seat (A), seat underlayment (B), leg panel (C), frame side (D), stretchers (E), shelf (F) and stiffener (G).

2. Smooth the sides and bottom edges of the legs, the top edges of the stretchers, and all the edges of the seat and underlayment with a sander or a router and 1/4" roundover bit.

ASSEMBLE THE SHELF AND STRETCHERS.

All the plywood parts are connected with screws and glue. Before you drive any screws, drill counterbores for the screw heads that are just deep enough to be filled with wood filler or putty.

1. Attach the stretchers (E) to the shelf (F) by drilling four evenly spaced 1/8" pilot holes through the outside edges of the stretchers and into the front and back edges of the shelf. Keep the screw holes at least 2" from the ends of the stretchers to prevent splitting.

2. Glue the joints (photo A) and drive 2" deck screws through the pilot holes and into the shelf.

Use glue to reinforce the joints between the stretchers and the shelf.

BUILD THE BOX FRAME.

1. Attach the two frame sides (D) to the ends of the shelf assembly. Begin by measuring and marking a line 2" up from the bottom edge of each frame side. The stretcher's lower edges will fit here.

2. Position the stiffener (G) between the frame sides at the top centerpoints. Mark the stiffener's position, making sure the top of the stiffener is flush with the tops of the frame sides. Apply glue to all the joints.

3. Clamp the stretchers and stiffener in position with bar clamps. Drill two evenly spaced 1/8" pilot holes through each frame side and into the ends of the stiffener. Drive in 2" deck screws to secure the stiffener (photo B). For extra shelf support, drill pilot holes and drive a screw through the center of each frame side into the shelf.

The stiffener is screwed in place between the sides to keep the boot butler square.

COMPLETE THE LEG ASSEMBLY .

Attach leg panels (C) to the outer faces of the frame sides to provide wider, more stable support points for the seat.

1. Put wax paper or newspaper on your work surface to catch any excess glue. Apply glue to the outer face of each frame side and to the inner face of each leg panel. Press the leg panels against the frame panels, centered side to side to create a 1/2" reveal on each side of each frame panel. All top and bottom edges should be flush. Clamp each panel pair together (photo C).

A pair of plywood panels are fastened together to create each leg assembly.

2. Drill pilot holes in the frame sides and counterbore the holes. Drive 1 1/4"deck screws through the frame sides and into the leg panels.

3. Measure the box frame diagonally from corner to corner, across the tops of the leg assembly to make sure it is square. Use a pipe clamp to draw the frame together until it is square and the diagonal measurements are equal (photo D).

If the frame isn't square, fasten a pipe clamp diagonally across it and tighten.

ATTACH THE SEAT.

The seat for the boot butler is made of an underlayment (B) layered with a plywood seat (A).

1. Lay the underlayment on a flat surface. Turn the leg and shelf assembly upside down and center it on the bottom face of the underlayment. Outline edges of the frame onto the underlayment (photo E).

Set the frame assembly onto the underlayment. Center and trace the outline on the underlayment.

2. Flip the leg and shelf assembly upright. Apply glue to the tops of the legs and stiffener. Position the underlayment on the assembly according to the alignment marks.

3. Drill 1/8" pilot holes through the underlayment into the legs and stiffeners. Counterbore the holes. Drive in 2" deck screws.

4. Apply a thin layer of glue to the top of the underlayment and the underside of the seat. Position the seat on the underlayment so the overhang is equal on all sides. Set heavy weights on top of the seat to create a solid glue bond (photo F).

5. Drill evenly spaced pilot holes in the underlayment and counterbore the holes. Drive 1 1/4" deck screws through the underlayment into the seat.

APPLY FINISHING TOUCHES.

1. Fill all of the counterbored screw holes and plywood edges with wood putty and sand smooth.

2. Apply primer and paint. For a decorative touch, stencil or sponge-paint the surfaces.

Tip

Rigid, clear plastic boot trays are sold at most discount stores or building centers. The Boot Butler project shown here is designed to hold 15 × 21" plastic boot trays.