How to Build a Picnic Bench
- 1). Cut the vertical legs. Cut two of the two-by-fours down to four pieces, 30 3/4 inches long each, with a 22.5 degree angles on each end of all four boards. To do this, cut four 32 1/4 inch pieces, then cut the ends at a 22.5 degree, so a small triangle is cut off either end. Be sure you cut your angles in the same direction so either side of the board measures 30 3/4 inches and both angles are parallel.
- 2). Cut the two top cross braces for the frame using one more of the two-by-fours. The two top cross braces should each measure 30 1/2 inches long, so you can use one 6-foot board to cut both top cross braces. These two cross braces also need a 22.5 degree angle cut from both edges. However, these angles should not be parallel; the bottom of the board should be longer than the top of the board. The bottom of the board should measure 30 1/2 inches.
- 3). Cut the two bottom cross braces for the frame using two more of the two-by-fours. The two bottom cross braces should each measure 54 1/2 inches long, with no angles cut off the edges.
- 4). Lay two of the vertical legs on a flat surface to begin assembling the side frames. Place the top cross brace on top of the legs, so the angles line up. Place the bottom cross brace on the middle of the frame, parallel to the bottom of the legs (parallel to the ground when the frame is standing). Use a hammer and nails to temporarily secure the cross braces to the legs. Hammer one nail on each side of both cross braces, but do not center the nail; the nail just holds the wood together until you permanently attach each piece. Repeat for the second side frame.
- 5). Drill a hole in the center of each point where the cross braces intersect with the legs (four total points on each side frame: two for each top cross brace and two for each bottom cross brace). Use a 5/16-inch drill bit. Then, use the 5/16-inch by 3 1/2-inch carriage bolts, washers and nuts to attach the cross braces to the legs: insert the bolt from the outside of the leg through the hole so it comes out of the hole on the inside of the cross brace. Place a washer on top of the bolt, and a nut on top of the washer, and tighten. Do this for all eight holes you drilled (four on each side frame).
- 6). Stand one side frame upright. Place two of the 6-foot two-by-fours on top of one side of the bottom cross brace. These two boards are the bench for one side of the table. The benches should stick out eight inches on the outer side of the frame. Use the 2 1/2-inch deck screws to attach the bench boards to the bottom cross brace. Grab the other side frame and attach the other end of the bench boards to the corresponding bottom cross brace. The bench boards should extend eight inches past that frame as well. Repeat the process with two more bench boards on the other side to make the other bench. Once you are finished, both benches are assembled.
- 7). Place the four 1-inch by 8-inch boards on top, which will be the table top. Align all four table top boards so they stick out eight inches past the frame on both ends. Use the 1 1/2-inch deck screws to attach the table top boards to the top cross braces of the frame. Leave a small opening, about the width of a screw, between each of the four table top boards.
- 8). Use one of the remaining two-by-fours to cut a 29-inch support brace, with 22.5 degree angles at either end, similar to the top cross braces in the side frames. Attach the support brace with the longer side against the table top boards to the center of the underside of the table top, running perpendicular to the benches. Use 10 2 1/2 inch screws to attach the beam by drilling the holes in the center of the table top and screwing the support brace on the underside of the table top. This adds more support to the bottom of the table.
- 9). Flip the table upside-down. Cut two 8-inch support braces from the two-by-four you used to cut the 29-inch support brace. Attach one 8-inch brace to the center of the underside of each bench. The brace should run perpendicular to the bench. Use a drill and four 2 1/2 inch screws to attach the brace to each bench. This adds more support to either bench.
- 10
Cut the remaining two-by-four into two 31-inch pieces. Cut parallel 28 degree angles on the ends of both boards. Both sides of the board should be the same length after the angles are cut. Cut 1/2 inch of material from the long tip on either end of both boards: measure 1/2 in from the tip, draw a 90 degree angle line from that point, and cut along that line. Connect each angled brace from the center support brace (underneath the table top) to the center of the bottom support brace on either side frame. These diagonal support braces run parallel to the benches. Use four 2 1/2 inch screws to connect both angled support braces. - 11
Fill any screw holes with exterior filler and sand the table down. Prime and paint it as you please.