DIY Outdoor Bench

How to Build a DIY Outdoor Bench

1. 1 Cut the Stock

   

   Cut the following pieces from the 2 x 4 stock, using the BLACK+DECKER 20V MAX* 5 1/2 in. Circular Saw:

   • (2) pieces, 72" long for the deck
   • (2) pieces, 64" long for the apron sides
   • (8) pieces, 16" long for the legs
   • (4) pieces, 5" long for the apron ends
   • (2) pieces, 8" long for the center supports

   Cut one piece of 2 x 6, 72" long for the deck.
   

2. 2 Build the Leg Supports

   

   Use a pocket hole jig, the BLACK+DECKER 20V MAX* Lithium 2-Speed Drill/Driver and 3/8" step bit to drill holes at regular intervals along one side of all the apron pieces. Repeat on the ends of the 5" apron end pieces and the ends of the center supports.

   Apply weather-resistant glue to the ends of the 5" apron pieces, and fit them between two of the 16" legs, flush at the top. Fasten the pieces together using the pocket holes in the ends, with 1 5/8" pocket hole screws. Build four identical leg supports. (They should look like an upside down "U", with the horizontal 5" piece at the top.)

   TIP: The 3/8" step bit works in conjunction with the pocket hole jig. The 3/8" step is a countersink bit, with a 1/8" pilot bit on the end. The other end of the bit has a built-in stop to control the depth of the hole.

3. 3 Build the Base

   

   Build the leg assembly upside down. Start by placing two of the leg supports upside down on a work surface. Apply glue to the ends of the two 64" apron pieces and fit them between the leg supports at the corners, flat on the table. Fasten the leg supports to the apron pieces with 2 1/2" screws.
   
   

4. 4 Overlay the Supports

   

   Apply weather-resistant glue to the two remaining leg supports and overlay them on the outside ends of the leg assemblies. Screw them on with 2 1/2" screws. This will result in 3" thick legs.

   Apply glue to the ends of the two 8" center supports, and fit them evenly spaced between the 62" aprons, flush with the top. Screw them on using 3" screws.

5. 5 Sand Everything + Apply Finish

   

   Use the BLACK+DECKER MOUSE® Detail Sander with 100-grit sandpaper to sand all the parts smooth. Round and blunt all corners and edges. Apply stain and exterior finish to the sides and underneath of the decking boards before assembly, and to the bottom ends of the legs. (It's difficult to get the finish in the cracks and underneath after assembly.)

6. 6 Add the Decking

   

   Place the 72" long 2 x 6 and two 2 x 4 decking boards on a flat surface, with the 2 x 6 centered between the 2 x 4s, allowing a 1/2" gap between all of them. Center the leg assembly upside down on the decking boards.

   Screw the leg assembly to the decking with 1 5/8 inch pocket hole screws, utilizing the pocket hole screws in the apron pieces.

7. 7 Finish the Bench

   

   Apply your choice of stain and one or more coats of exterior wood finish. Follow the manufacturers' instructions for application and drying times.

8. 8 Complete + Use!