When I began this project the first thing I did was create a cutting diagram. That is simply a matter of laying out the pieces on a diagram to scale. You can do it the old-fashioned way, drawing on paper, or there are simple-to-complex computer programs that will do the calculating for you.

Need a bench in the garden that will also hold your gear? Thinking about making toy boxes for the kids' rooms? Want more seating and storage for the porch or garage?

The construction is simple, easily done in one weekend, but the benches are plenty sturdy with room for stashing stuff. And the thrifty among you will appreciate that the total cost of materials is only about $50.

I tackled this project because my dog club, the Cairn Terrier Club of Southern California, needed seating and storage for a "meet the breed" booth at the American Kennel Club/Eukanuba National Championship, Dec. 2-3 in Long Beach. A club member came up with a simple design and I pitched in to do the construction.

I started by using 3/4 -inch plywood to make the carcasses for both cases. For the inside bottom I got a small sheet of half-inch medium density fiberboard (MDF).

Cut all the pieces to size (see cut list) on a table saw or with a circular saw. For clean cuts use a blade made for plywood and keep the best side facing toward the cutting motion of the blade – up on a table saw, down on a circular saw.

Draw the cutouts on the bench fronts and sides (see illustration on Page 14). For the curved intersections, trace a round object such as a small paint can.

To hold the bottom in place, make dado cuts in the fronts and sides about eight inches up from the base. I used a plunge router with a 1/2 -inch straight bit (see photo at lower left) to make a half-inch wide, 5/16 -inch-deep channel across the sides. On the front and back you need to stop the dado cut just short of the ends; otherwise they would show in the finished piece. My guide has a micro-adjuster that makes it easy to make a second pass to widen the channel slightly so the fit isn't too tight.

Use a jigsaw, band saw or scroll saw to cut out the insets. I used a scroll saw because it leaves a smooth finish.

Overlap the front and back pieces on the sides and drill pilot holes for three screws at each corner edge. Use a counter-sink bit so that the screws will be inset. Tip: Use a clamping square to ensure alignment (see photo on Page 1). You can use spackling or filler to cover them later, making a smooth surface for painting.

Instal
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