wj088 garden bench

7/25/2019 WJ088 Garden Bench

1/13

Step by Step constructioninstruction.

A complete bill of materials.

Exploded view and elevationdrawings.

How-to photos with instructivecaptions.

Tips to help you complete theproject and become a betterwoodworker.

To download these plans,you will need Adobe Reader

installed on your computer. If you want to geta free copy, you can get it at: Adobe Reader .

Having trouble downloading the plans? If you're using Microsoft Internet

Explorer, right click on the download linkand select "Save Target As" to downloadto your local drive.

If you're using Netscape, right click onthe download link and select "Save LinkAs" to download to your local drive.

WJ088

Americas leading woodworking authority

Hoopback Garden Bench

Published in Woodworkers Journal Practical Woodworking:Proven Projects, Tips and Tricks from Fellow Woodworkers

WOODWORKER'S JOURNAL

2007 ALL RIGHTS RESERVED


2/13

96 HOME PROJECTS

WOODWORKER'S JOURNAL 2007 ALL RIGHTS RESERVED


3/13

If your patio seating amounts to acouple of plastic chairs or straddling apicnic bench, maybe its time to addone of these garden benches to yourlist of options. At more than five feetlong, it will easily seat three adults.

The backrests gentle angle and closespacing of the seat slats means its alsoquite comfortable.

We could have simplified the projects design by incorporating fewercurves, but a curvy bench seems toharmonize well with the irregular shapesof outdoor spaces and flowerbeds.

The armrests and crest rail, in particular,make the bench feel more organic,informal and inviting.

A weather-resistant wood speciesis a must for this project. Our authorused reclaimed sinker cypress (see tint

box , page 98), and it was a pleasureto build with. If youve never tried it,cypress cuts, routs and sands similar tocedar or redwood. Its not oily, has apleasant odor and glues up without

The author fixed a leg template to each leg blank and left it there for the entire machining process. Drill the mortise for the seat rail before you cut the back leg out of its blank.

HOOPBACK GARDEN BENCH 97

Hoopback Garden BenchG raceful curves make the style of this bench timeless, while reclaimed cypresslumber will stand up to the worst weather, season after season. As far as outdoorprojects go, this bench requires a fairly ambitious effort and several weekends of time to

complete, but its rugged construction will be worth all your efforts.

issue. Take the usual precautions whencutting or routing to minimize end graintearout and splintering.

Templates and More TemplatesLaying out and assembling this

bench will go much easier if youstart with some full-size patterns andtemplates. Make a full-size griddedpattern of the benchs end viewitll bea real help for positioning the armrestsand setting up the rail angles. Youshould also fabricate hardboard tem-plates for the crest rail, back leg, arm-rest (both side and top views), seat railand front rail. The templates will be

handy for locating mortises and for tem-plate-routing the rough parts to finalshape. Use the elevation drawingsprinted throughout this article to makethese shop aids. Its worth the fuss.

Making the End FramesGet rolling on this project by build-

ing the end frames, which consist of thefront and back legs and the seat andlower rails (pieces 1 through 4).

Start with the back legs. Use yourback leg template to draw the legshapes on some 8 1 2"-wide stock. Orientthe leg shapes so the longest flat edgesof the legs line up with a stock edge.

At this time, we suggest that you stick the template to each leg blank with hot-melt glue or carpet tape. Mark and cutthe seat rail mortises using whatevermachining method you prefer (see

photo , above). We drilled them out witha Forstner bit. Cut out the leg shapes,and refine them with a piloted, flush-trim bit in the router table. It will save



4/13

98 HOME PROJECTS

During the late 1800sand early 1900s, loggersused rivers for transportinglogs to lumber mills. InSouthern states much of this timber was virgincypress, ranging in agefrom 300 to 1,200 yearsold. Some logs sank while in transit, wheretheyve remained largelypreserved under layersof mud and silt. KrantzRecovered Woods, our lumber supplier for this bench, harvests these sinker logs fromLouisiana lakes and rivers. The logs are sawn into boards and beams, then thoroughly air-driedbefore theyre sold.

Virgin cypress trees matured slowly in dense, ancient forests. Recovered logs exhibit a whopping 30 to 50 annualgrowth rings per inch! The trees in todays second-growth forests average only five to 10 rings per inch. Higher ringcounts make antique cypress exceptionally stable, fine-grained, largely free of knots and naturally insect- and rot-resistant.

Krantz offers sinker cypress in 4/4, 8/4 and beam thicknesses in widths up to 12" and in lengths up to 30'. Pricesrange from $4 to $8 per BF, plus shipping. To learn more or receive a price quote on lumber, call Krantz RecoveredWoods at 888-242-1050, or visit them on the web at: www.KrantzRecoveredWoods.com.

Recovered sinker cypress logs remained largely preserved under layers of oxygen-poor mud and siltfor over a century.

To rout the angled shoulders on the back legs toptenons, make a jigthat registers the

angles and clamp it to both legs. Thisway, you can mill them in one setup. A rub collar on your

router can follow the angled jig shapes to cut the shoulders. Flip the legs over in the jig to

make the second set of angled shoulders.

you loads of sanding time. Cut thelower rail mortises with a router, 3/4"straight bit and edge guide. Both railmortises are offset on the legs to create1/4" shadow lines between these parts.

Turn to the top leg tenons next.Notice in the drawings and in the inset

photo (below), that the front and back shoulders are angled to accommodatethe curved crest rail. The bent legshape wont allow for cutting theseangled shoulders on a saw, but you canrout them with a simple jig, rub collarand straight bit (see photo , left). Theother pair of square shoulders andcheeks on these tenons can betrimmed to shape with a band saw.

Both the seat rail and lower railshave angled tenons where they attachto the back legs. Cut the rails to sizenow (but dont cut the seat rail arches

yet), and make the angled shouldersof these tenons on the table saw witha wide dado and the miter gauge setto 75. Cut the short cheeks andshoulders on the band saw. Make thestraight front tenons on these parts inthe usual way, then cut the seat railarches. Flush-trim the arches at therouter table using the seat rail templateas the bearing guide.

The front legs have tenons on topwith angled shoulders similar to theback legs. Since these legs are straight,cut the angled shoulders at the tablesaw with the miter gauge set to 75.

Trim the front and back shoulders andcheeks to shape at the band saw.

Wrap up the front leg joinery bycutting mortises for the seat rail, frontrail and lower rail. Keep the orientationof the front legs clear as you mill these

LOWDOWN ON SINKER CYPRESS



5/13


The back slats fit into individual mortises in the back rail. A hollow chisel mortiser is the perfect tool for this repetitive chopping task. Or,

you could cut them with a plunge router fitted with an edge guide.

Rout the shallow step of the crest rails continuous slat mortise first.Plow it from one back leg mortise to the other. Then mill the 3/4"-deep stopped portion of the slat mortise with the same bit and edge

guide setup.

mortisesthe legs are mirror images and not identical.Dry-fit the end frames, then give the parts a good sand-

ing. After that, ease the edges and glue up the frames.

Making the SeatFollow the Material List on the next page to cut the front

and back rails and the seat supports (pieces 5 through 7) tosize. Mill tenons on the ends of the front rail. Attach the frontrail template temporarily, trim the broad arch about 1/16"proud of the template edge, then refine the shape with aflush-trimming bit and your router.

The back slats fit into a series of individual mortises inthe back rail. Use the Elevation Drawings on page 105 to laythese mortises out, and mill them. Some bench designs will

substitute a long, continuous mortise here and separate theslats with spacer blocks, but our author wanted to minimizeexposed horizontal glue lines wherever possible. The fewer

joints where water can soak in and cause trouble, the better. The back ends of the seat supports are angled to hold

Quick Tip

Storyboards Keep PartOrdering ClearLarge assemblies with numerousparts can quickly get out of hand,so the pros know the value of astoryboard to keep everythingorganized. This can be as simpleas a large sheet of paper or hard-board laid on the workbench, witha full-size template drawn on it.The template shows how the partswill be oriented to each other afterassembly, and a good template caneven be used to take measurementswhile you cut parts to size. Hot gluesmall guide blocks to the template,to help line up the larger parts.



6/13

Bench Exploded View

100 HOME PROJECTS

111

2

3

45

6

78

10

9

13

14

12

MATERIAL LIST BenchT x W x L

1 Back Legs* (2) 1 3 4" x 8 1 2" x 33"2 Front Legs (2) 1 3 4" x 2 1 4" x 24 1 4"3 Seat Rails (2) 1 1 2" x 4" x 17 3 4"4 Lower Rails (2) 1 1 2" x 2" x 19 1 2"5 Front Rail (1) 1 1 2" x 5 3 4" x 65"6 Back Rail (1) 1 1 2" x 4" x 62 1 2"7 Seat Supports (2) 1 1 2" x 2 3 4" x 16 1 4"8 Seat Slats (5) 3/4" x 2 3 4" x 66"

T x W x L

9 Crest Rail* (1) 1 3 4" x 8 1 4" x 71 1 4"10 Narrow Back Slats* (14) 3/4" x 4" x Varies11 Wide Back Slat (1) 3/4" x 7" x 21"12 Back Slat Spacers (14) 3/4" x 3/4" x 1"13 Armrests (2) 4"* x 4 1 2" x 25"14 Dowel Pins (30) 3/8" Dia.

*Width dimensions are prior to shaping



7/13


1 2

3

4

8

9

13

3"

2 1 / 2"

1 1 / 2"

1 / 2" typ.

11 1 / 4"

15"

26"

11 1 / 4"

17"

18"

38"R.

38"R.

C L

Hoopback Garden Bench(End View)

the back rail in the same plane as thecrest rail. This way, the back slats will fitinto straight, rather than angled, mortis-es. Attach the seat supports to bothlong rails with pairs of countersunk 4"deck screws at each joint. The topedges of the seat supports should beflush with the back rails mortised edge,but be careful that the supports attach3/4" down from the top edge of thefront rail. This way, the seat slats willalign with the top edge of the front rail.

Now join the front and back rails tothe end frames to erect the bench seat.

The back legs attach to the back rail withpairs of countersunk 4" screws. Gluethe front rail tenons into their mortises.Line up this center bench subassemblyso the back rail and seat rails alignproperly, as shown in the drawings .

Cut the five seat slats (pieces 8) tosize, and round over the edges andends. Instead of attaching these slatsby driving screws down into the railsand seat supports, use dabs of water-resistant glue to tack them in place, thendrive weather-resistant 1 1 2" pocketscrews up from underneath (see photo ,page 104). Its a good way to avoid rowsof unsightly wood plugs on the seat slats.

Moving on to the Back The curved crest rail (piece 9) is

easier to machine while its still part of awider, flat-edged blank. Stick the tem-plate to your stock so the bottom curvefaces up and the pointed tips are flushwith the stock edge. Cut the crest railsinner curve and trim it flush with arouter. The back slats fit into a continu-

ous groove in this curve. Refer to theElevation Drawings on page 105 to seehow it steps from a depth of 5/16" to3/4" for most of the length. The shal-lower part of the mortise helps keep theback leg mortises strong while still hid-ing the top ends of the endmost back slats. Set up your router and edgeguide to cut the 5/16" mortise depthfirst, and mark the back leg mortiselocations. Rout the shallow portion of the step from one leg mortise to theother (see photo , page 99), then contin-ue to hog out the deeper slat mortisesto a depth of 3/4", stopping 1 3 4" fromeach of the back leg mortises.

With the continuous mortise com-pleted, bore the back leg mortises onthe drill press with a 1 1 4"-diameterForstner bit, and chisel the corners

CYPRESS DOWELS

Where can

you find cypressdowels? In yourscrap bin. Makeyour dowel pegsat the router tablewith a 3/8"-diameter bullnose bit. Clamp a scraptunnel against the fence to keep the dowels fromchattering during milling. Run strips of square stock through the tunnel twice to round half of the curvaturewith each pass.



8/13

102 HOME PROJECTS

Drawing parallel curves on the back slats is easy if you group the slats together in a jig. Make a template with a curve based on a 9-foot radius, and trace the curves onto the slats using the template. Shape the slat jig so the top edge matches the crest rail mortise curve. This way, youcan scribe the slat top curves as well.

square. The flat bottom edge of thecrest rail blank will ensure that thesetwo mortises are square to the back legs. Once the leg mortises are done,finish cutting out the crest rail, routit flush to the template and ease theedges with a 1 4" roundover bit.

The back slats start out as 4" or7" straight-edged blanks but end upcurved along both long edges. Wetackled the task of marking thesecurves by butting the narrow and wideback slats (pieces 10 and 11) next toone another inside a jig (see Back Slat

Jig , page 107). First cut the bottomtenons on the slats, then set them inthe jig whose top curve matches theshape and position of the crest rail mor-tise at full depth. Then mark the curvedtop line (which determines the slatlength as well) using the jig. Whenyoure done, flip the slats over and

Initially, our author wasnt sure which armrest style would look best on hisbench, so he made several prototype armrests from scrap (above). This is agreat way, especially on a chair or bench project, to help you settle form,function and ergonomic issues.

PROTOTYPING



9/13


Sawing the armrests to shape is a two-stage technique. Cut the side profile first, tape theoff-cuts back in place, then cut the top profile (shown here). Once theyre shaped, clamp the

armrests in a drilling jig (see inset photo, left) to drill out the front leg mortises.

Cut out a portion of your full-sized bench end view pattern to make an alignment jig for drilling the armrest mortises. The goal here isto cut these mortises so the legs meet the

armrests squarely, despite the curve.

rearrange them in the jig so the curvedcutoff line shows on top. Use a shorttemplate in the jig to draw the curved

edges on the slats, one after the next. All these curves match those on thecenter slat (see top photo , previouspage). Index the curves on the slats sothat each finished slat will be 1" apart.Make the center slat 6" wide and theother slats 3" wide. Leave the endmost

slats flat on their outer edges wheretheyll meet the back legs.

Gang-cut the narrow slats in stacksof three or four on the band saw, thencut them to length individually. Smooth

the slat edges. Note in their elevationson page 105 that the endmost slatsneed to be notched at the top cornersto fit into the stepped crest rail mortisewhere it changes depth.

Quick Tip

Instant Workbench ViseMost workbenches have two vises thatallow you to work at either one side oran end. If your bench only has one viseat the end, heres a way to add a sidevise wherever you need it. Rout a slotalong your bench and embed a lengthof metal T-track to hold a couple of 10"handscrew clamps. Then drill a hole in

each clamp and insert a T-bolt that fitsin the track. A wingnut makes adjust-ing easy. Sliding one clamp in fromeach end gives you an instant vise.



10/13

104 HOME PROJECTS

To hide the seat slat fasteners, drive them in from underneath. The author used a pocket-hole jig and weather-resistant pocket screws. Tack the slats in place first with glue.

Test-fit the slats and crest rail on thebench. When it all assembles without

force, slip the slats into the back rail andcrest rail mortises dry, but glue the crestrail onto the back leg tenons. Cut slatsspacers (pieces 12) to size, and use dabsof glue and galvanized finished nails topin them into place in the long mortise.

Adding the ArmrestsMake blanks for the armrests

(pieces 13) by building up two thick-nesses of 8/4 stock. Notice that thefinal armrest shape is curved both

lengthwise and widthwise. Heres howto sculpt the shape: Use your ArmrestSide View Template to draw this portionof the curvature, then band-saw theshape. Save the offcuts and tape themback in place to reform the blanks.Now, use your Top View Armrest

Template to mark this dimension of thecurvature onto the blank. Saw the arm-rest to shape here, and remove all theoffcuts (see top photo , page 103).

If you made a full-size end view pat-tern of the bench, locating and making thearmrest mortises for the front leg tenonswill be a snap. Remove a portion of yourpattern directly above the armrest and useit as the reference for making a drilling jigthat holds the armrest square, relative tothe front leg (see inset photo , page 103).Mount this section of your pattern to somethick scrap, cut the scrap to match yourpattern curvature, and attach it to a scrapbase. Then, boring the armrest mortiseson the drill press will be a simple matter of clamping them against the jig, marking themortise dimensions off the pattern anddrilling the stopped mortise holes. Squareup the mortises with a sharp chisel, andrefine the armrest with a good dose of belt-sanding. Ease the edges with a 1/4"or 3/8"-diameter roundover bit .

Set the armrests against the front andback legs to determine where to notch the

armrests so they fit around the back legs.Cut these notches out with a hand saw.Install the armrests with glue in the mortiseand tenon joint and with a 1/4" x 2" coun-tersunk galvanized lag bolt and washer tothe back legs.

Pinning the JointsGlue alone will certainly hold these

mortise and tenon joints for a longwhile, but eventually the glue might fail.

As added insurance, its a good idea topeg all the interlocking joints and plugthe screw holes with 3/8"-diameter

cypress dowel pins (pieces 14). Youcant buy cypress dowels, but theyreeasy to make on the router table witha bullnose bit. Two passes through ascrap tunnel jig turns square strips intoperfect doweling (see the sidebar onpage 101 for details).

Trim the dowel pins and sand themflush, then give the bench a coat of pen-etrating wood finish to help preserve itscolor. All thats left now is to move yournew bench outside, rustle up the tikitorches and start planning your nextpatio party.



11/13


Technical Drawings

Bench Back Subassembly

Front Rail (Front View)

Back Rail (Top View)

Back Rail (Front View)

(Front View)

101011

5

6

6

9

12

3 / 4 "3 / 4 "

1 / 2 " 2 1 / 4 "

13

/ 4 "

31 1 / 4 "

2"

9'0" R.

5 1 / 4 "

20"

3 / 4 "

18'0" R.

9'0" R.

C L

The 3/4"-deep seat slat mortise changes to 5/16" deep at 1 3 4" from back leg mortises.

Notch for groovechange.

34" T. x 5" W. x 1 1 4" L. tenon12" roundover

Original slat width 4"



12/13

106 HOME PROJECTS

Technical Drawings

Although the back slats have curved edges, keepthe bottom tenons straight. This way, theyll fit into

straight mortises milled in the back rail.

NOTE: Given the shape of the back legs, youll need

to cut the upper mortises without the aid of a table saw. Use a router, rub collar and jig to make thesetemplate style (see page 98). The angled mortiseson the front legs can be cut conventionally, sincethe legs are flat.

Seat Support (Side View)

Lower Rail (Side View)

Seat Slats and Rail (Side View)

10

1 / 2 "1 / 2 "

4

7

38" R.

3

8

38" R.

Back Slat Layout Detail

34" T. x 3 1 4" W. x 78" L. tenon

34" T. x 1 1 4" W. x 1 1 4" L. tenon

34" T. x 1 1 2" W. x 1 1 4" L. tenon

34" T. x 3 3 8" W. x 1 1 4" L. tenon

Back Leg(Front View)

Front Leg(Front and Side Views)

1

22

3 / 4 "

3 / 8 "

3 / 4 "

3 / 8 "

3 / 4 "

3 / 8 "

3 / 4 "

7 / 8 "

31 1 / 4 "

3 1 / 4 " 5"

12 5 / 8 "

3 3 / 8 "

14 3 / 8 "

1 1 4" T. x 1 1 4" W. x 1 5 8" L. tenon at longest shoulder.

1 1 4" T. x 1 3 4" W. x 1 1 4" L.tenon at longest shoulder.

17 tenon shoulder

I n s i d

e e d g e

I n s i d

e e d g e



13/13


63"

21"

106 3 / 4 " R.

Back Slat Jig

The key to accurately forming the back slats is to create the jig shown above. The jigs curved edge is shaped to match thecrest rail mortise groove. Lay the slats in the jig and mark their curved top ends, using the curved edge of the jig. Next flip the

slats over and move them end-for-end on the jig so the curved line you drew is showing. Now use a template (see the photoon the top of page 102) to lay out the curved edges of the slats,

represented by the dotted lines above. There needs to be a 1" space between the curved parallel lines.

Armrest (Top and Side Views)

1

13

13

Each square equals 1"

Back Leg (Side View)

wj088 garden bench

Documents