Step 1: Set the Backrest Angle
Step 2: Attach the Back Rails
Step 3: Secure the Slats
Step 4: Finish the Frame
Step 5: Start Your Cushions
Step 6: Make the Piping for the Cushions
Step 7: Assemble the Top Cover
Step 8: Finish the Covers
Step 9: Attach the Buttons
On the edge of the sides, mark 1 9/16-in. from one end and mark a line up to the top corner, making a 15° angle, and cut with a circular saw. Position the ends between the sides with the front flush and the rear end aligned with the 1 9/16-in. (see diagram below), drilling 1/16-in. pilot holes and countersinking to secure with adhesive and #6 x 2-in. screws.
Position the back rails against the rear of the feet. Transfer the angle to the base of the rails and plane so the rail base sits flat. Drill 1/16-in. pilot holes through the rails into the sides, securing with adhesive and screws.
Position the feet spaced 18 3/4-in. apart. Position a slat flush to the front of the feet, securing with adhesive and screws. Position the remaining slats, drilling 1/16-in. countersunk pilot holes and securing to the feet and back rails.
Fill all screw holes with wood filler and leave to dry overnight. Use a random orbital sander to slightly round the edges, smooth the bench with 180-grit sandpaper, then apply two coats of gloss acrylic paint.
Cut double layers of mattress foam or high-density foam to 6-in. x 24-in. x 48-in. for the seat and 4-in. x 19-in. x 48-in. for the back. Buy 4 1/2-yards of 60-in.-wide fabric and follow the cutting list as a pattern. To make the piping, join strips of remnants for the two 144-in. long seat and 134-in. back pieces. Cut two lengths of 3/8-in. rope for the seat and two for the back.
Position the rope on the wrong side, folding the fabric over so the right side faces up, then machine stitch close to the rope for a tight fit.
Join the side and end pieces to the top with a 9/16-in. seam allowance, piping between, then machine stitch.
Machine stitch the base to the remaining piping. Turn the cover right side out and place it over the foam. Position the base piping and tack along the sides and ends, folding in the seam allowance. Use a slip stitch to hand sew the cover and enclose the foam.
Mark the button positions on both sides. Use heavy thread to attach buttons through the foam using a straight upholstery needle at least 10-in. long.
© 2012 Reiman Media Group, LLC.