With integrated seating for four, this sturdy outdoor setting is built from 3 1/2" x 3/4" treated pine boards that interlock like fingers.
Step 1: Angle the Cut Ends
Step 2: Cut the Half Lap Joints
Step 3: Test the Assembly
Step 4: Set Out the Leg Assembly
Step 5: Drill the Bolt Holes
Step 6: Make the Seat Template
Step 7: Cut Out the Seat Rails
Step 8: Complete the Seats
Step 9: Assemble the Table
Step 10: Finish the Wood
Use a protractor to set a sliding
bevel at 75° to mark opposing angles
on the crossrails and parallel angles on
the ends of the legs so they lean
towards the center and cut using
a jigsaw or sliding compound miter saw.
Mark the 3/4" wide half lap
joints on the crossrails, checking the
orientation, then use a jigsaw to cut
them 1 3/4" long, half the width of
the rails. Use a hammer and chisel to
remove the waste.
Connect the crossrails to check
the accuracy of the double half laps,
adjusting as necessary then sand the
parts with 180-grit abrasive paper and
apply two coats of exterior acrylic paint.
To mark the bolt holes, position
the legs and crossrails on a level
surface with a straightedge against the
angled base of the legs, keeping the
crossrails parallel to the straightedge.
Mark the overlapping areas then draw
a diagonal line across the intersection.
On each diagonal line, 1 1/4"
from the ends, use a drill and 1 1/4"
diameter Forstner bit to make 1/3"
deep holes on the outside legs for
the washers and nuts. Use a drill
with a 1/2" bit to drill the rest
of the way through.
On cardboard draw a 2"
square grid to sketch the rail shape
using the template. Cut out the
shape and transfer it onto 14 1/2"
lengths of 3 1/2" x 3/4" treated pine
to cut 20 rails.
Use a jigsaw to cut out the rails,
staying outside the marked
lines. Clamp the rails in bundles
of five to use an orbital sander with
100-grit then 180-grit abrasive paper
to sand and round over the edges.
Set the seat rails parallel with
3/4" spacers between the middle
three and 5 3/4" to the outer rails
then use 1/4" spacers to position
the slats with alternating finishes,
securing with screws.
Position the legs and crossrails
then secure using pairs of cuphead
bolts, washers and locking nuts.
Space the top slats using 1/4"
spacers, securing to the supports with
screws using stringlines as positionals.
After cutting the frame parts, seat
rails and tabletop supports, apply
two coats of exterior gloss acrylic.
To make a feature of the slats,
alternate finishing half of them in
a clear exterior gloss and the other
half with an exterior varnish stain.
© 2012 Reiman Media Group, LLC.