2×4 cross-legged bench

The bench is made entirely from 2×4 treated timber, assembled with screws, except for the stretcher, which incorporates two threaded bars extending from one side to the other, securing both legs with nuts and washers. Although its design resembles a dining bench, its height is not suitable for table use. However, it is ideal for a patio, porch, or as a sunbathing seat. It provides a welcoming spot for someone to sit and greet returning loved ones with a smile. The durable finish in antique pine colour makes it an excellent addition for the front of my newly painted house. I built that bench for two reasons: firstly, the old one was in poor condition, and secondly, even if it weren’t, it wouldn’t complement the newly painted walls of the house.

I began by cutting the legs to the desired length at a 30-degree angle. Next, I trimmed the stretcher to an approximate length and cut off its two sides with my table saw. Employing a dado blade, I cut a groove on each side, ensuring it was deep and wide enough for the threaded bar. To centre the groove accurately, I passed the stretcher over the blade, then flipped and rotated it to negate any centre-finding errors. With the dado blade still in place, I proceeded to cut lap joints on the legs. Since all the legs were uniformly wide, I utilised the stop block on my mitre gauge to guarantee that all the half-lap joints were consistent, beginning and ending at the exact same points on all four pieces. This method also provided safety by pressing the workpiece against the stop-block, preventing any movement and shifting during the cuts. The joints were not cut to perfectly overlap due to the rounded edges – if they were made perfectly flush with the adjoining piece, it would result in a shadow line, making the joints appear loose. I use this approach very often when working with rounded-over stock, the final products usually look better when joined that way.

One of the 2×4 off-cuts was ripped in half to make 2 braces. To cut shallow rebates for the upper braces, I installed a sacrificial fence and advanced the blade into it. As the legs were not joined in one plane and weren’t flush with each other, asymmetrical rebates were necessary. I identified the outward-facing legs and slightly reduced the blade height for them. The upper braces only needed a simple ledge for support, not as deep as the crossed section of the legs. It was essential to secure the braces tightly against the ledge to ensure even distribution of force between the screws and ledge, preventing any sliding in the future.

I taped off the ends of the bars using painter’s tape, applied adhesive, and attached the sides to the stretcher using my 18-gauge nailer. I inserted the bars and shifted them to clear any excess glue from the channels. Next, I attached the braces with two screws per leg and proceeded to my pillar drill to create 8-mm holes for the bars. I marked a perfectly centred line at a 90-degree angle to the braces, that were already in place at that point. Utilising a stretcher off-cut, I marked the drilling points and commenced drilling. After positioning the bar in the legs, I used my special tape to measure the length to trim the stretcher to, ensuring I did not cut through any brad nails. The orientation of the 3 top boards was carefully selected and the grain line faced up to take advantage of it in the future. The boards will very likely shrink and warp in the opposite direction of the rings resulting in tightening the screw connections and not working against them.

After securing the bars with nuts, I flipped the assembly over onto the top boards of the bench to mark the alignment lines. I then removed the stretcher and meticulously attached the legs to the top, paying close attention to the middle one. Any misalignment at this stage could lead to issues with fitting the stretcher or result in gaps that would weaken the joints. The strength of the stretcher joints was crucial to my design, ensuring the durability of the bench. Although it may have been excessive, and other methods might have sufficed, I wanted my design to be unique and original. Before I called it a day, I drilled holes for the rubber feet and tested the bench.

The following day, I smoothed the bench by sanding, softened all the sharp corners and sanded off pencil marks. I also cut levelling shims that were removable too (if need be) and attached the rubber feet. I predrilled the holes and tightened the screws manually. To purchase the Danish oil, I had to travel a great distance to the store, as it was the only place in my area that had in stock the specific shade – Antique Pine. Previously, I had used Canadian Cedar, which would be too dark for this bench, but I appreciated the qualities of that particular product. It was easy to apply, very forgiving, and extremely durable. Once the first coat had dried, I positioned the bench in front of the house to ensure that both the colour and the levelling shims functioned as intended in that location. The next day I applied the second and the last coat of oil and the bench was ready to go on the following day.

The colour of the bench harmonises with the freshly painted exterior walls and the PVC window frames. Achieving this was my goal, and I believe the task has been accomplished. Repainting the walls of your home allows for the updating of garden furniture as well, serving as a cost-effective complement to the larger renovation. However, constructing the bench was more time-consuming than painting the walls, strange, isn’t it? The method of attaching the stretcher to the legs draws inspiration from the tusk tenon joint, it functions similarly but looks like a modern reinterpretation. I like to think that way. The proportions of the bench are perfect, ensuring structural integrity and a compact appearance. All fasteners are hidden, except for two threaded bar ends and nuts, which are deliberately visible to demonstrate the construction and strength. Considering the previous bench lasted 7 years with one refurbishment, I hope the new one will surpass that. Meanwhile, I plan to enjoy it daily and make the most of it.