How to build bench seats with storage

GETTING STARTED

Template

• The easiest way to start this project is to make a template of your seat’s profile.
   
• The standard height for a bench seat is 400mm – 450mm. You can make the depth of your seat depending on your situation. Factoring in the foam that’ll sit on top, we’re making ours 400mm high.
   
• We’re also making it with a 15° angle on the front – this’ll stop your feet from hitting the front panel of the seat when you’re sitting on it. We’re also accounting for the top panel (lid), and front panel of 18mm ply, so are reducing both height and depth of our template by 18mm.
   
• Cut 6 of these – they’ll be the end panels and centre panel of your bench seats.

GETTING IT DONE

Seat Box

• End panel: Place end panel against the wall and screw into place.
   
• Wall plate: This will fit between your 2 sides of 18mm ply. So take 36mm off the length of your bench seat, and cut a piece of 60x20 baton that’ll fix against the wall, at the height of your template, between your 2 end panels.
   
• Floor plate: Cut a floor plate to the same length as your back plate, with a 15° angle on the front. Fix this in place on the floor according to your template. End panel: Screw your other end panel in place.
   
• Front panel: Cut your front panel with a 15° angle on the top and the bottom. Apply PVA glue, then screw into place.
   
• Centre panel: Use the template to create a centre panel. You’ll need to cut out notches to accommodate the wall & floor plates. Use off cuts of 60x20 to mark these out. Install this panel halfway down your bench seat, glue and screw it in place making sure it’s plumb.

Seat Top

• Front & back pieces: Cut 2 pieces of 60x20 timber to the length of your bench seat. Glue & screw these to the front and back.
   
• Middle pieces: Measure between the front & back pieces, and cut 3 lengths of 60x20 to fit. Glue & screw. Make sure they’re all square.
   
• Under boards: The plywood storage lids will sit on top of these. Measure all four sides and cut lengths of 60x20. Glue and screw to the undersides of the frame. Allow 2mm less for them to fit. Repeat for each storage compartment.
   
• Lids: Measure the space for each lid, take off 4mm, and cut the ply to fit.
   
• Finger holes: Drill 35mm finger holes in each lid, placed 100mm from each side, and 50mm from the front. First drill a small pilot hole. Then use a 35mm spade bit. You’ll want to drill half way through, flip the board over, and drill through the other side. This’ll stop the ply from cracking and splintering.
   
• Edges & finishing: Sand the insides of each hole and all edges, or use a trim router with a 3mm radius bit to round them all off. Then sand all surfaces with an orbital sander.

Return Bench Seat

• Use the same techniques to build the return section of your bench seat. Mark it off to your desired length, and use your template so the dimensions are the same all the way around your bench seat.
   
• Front & floor plates: Cut a 15° angle on the end of your back plate so it fits nicely against the front panel. Screw it in. Cut a 15° angle on the end of the floor plate. Screw it in place.
   
• End panels: Attach end panels. The end panel in the corner will need notches cut out to accommodate the wall & front plates. It should be installed plumb, NOT at a 15° angle.
   
• Front panel: Measure and cut the front panel. Leave it over-length, and mark a 15° angle (from your template) onto one end. This will allow it to fit into the corner. Sit it in place, and mark the other end to cut, using the end plate as a guide. Make sure the end plate is plumb when marking the front panel. Cut & screw into place.
   
• Complete: Use the previous instructions to build the rest of the return bench seat.

CUSHIONS

Baseplate

• Measure the top of your bench seats where the cushion will sit.
   
• Take 10mm off the length and width to compensate for the batting that will sit either side of the cushion.
   
• Cut a piece of 12mm ply to these dimensions.

Padding & Material

• Cut foam padding to length.
   
• Attach foam padding to ply with spray adhesive. Start from one end, line it up, and slowly roll it down into place.
   
• Lay down the material face down, place the batting on top. Then lay down the ply & foam, with the ply facing up. This is the back of your box cushion.
   
• Cut batting and material to size. Allowing enough material and batting to wrap around every side of the cushion, and at least 60mm onto the plywood.
   
• Wrap one side around and use a heavy duty staple gun to attach it to the ply. Don’t be afraid to use plenty of staples.
   
• Then staple the other side, making sure it’s stretched over nice and tight.
   
• Cut the extra sides off the batting so it doesn’t double up when folded.
   
• Ensure a neat 90° fold with no pleating.
   
• Staple in place, and repeat for the other end.
   
• Use the same steps to create your other box cushions.

Back Rests

• Use the same techniques to make your back rests, but use thinner foam.
   
• Attach them to your wall 130mm above the box cushions, making sure they’re level.
   
• There’s a variety of ways to attach them - a simple method is to use strips of heavy duty Velcro. They’ll be easy to remove for cleaning.