All said and done this project should cost you less than $200 and will provide you with a quality piece of furniture that you can break down and setup again and again!!
Step 1: The Plans
Step 2: The Parts and Tools
Raw Materials (got from Home Depot)
Qty | Description
1 | 4x8 Sheet of Plywood.
3 | 10.5 foot pcs of top rail fence post (1-3/8")
10 | Screws (with washers)
Kee Klamp fittings (got from http://www.simplifiedbuilding.com)
Qty | Description | URL
4 | 20-6 Side Outlet Elbow 1" | http://www.simplifiedbuilding.com/product_info.php?products_id=111
8 | MH50-6 Swivel Member | http://www.simplifiedbuilding.com/product_info.php?products_id=210
4 | 61-6 Flange 1" | http://www.simplifiedbuilding.com/product_info.php?products_id=258
2 | 105-6 Sheeting Clips | http://www.simplifiedbuilding.com/product_info.php?products_id=376
1 | Allen Wrench (for Kee Klamp fittings)
1 | Tape Measure
1 | Pipe Cutter
1 | Latex grip glove (for holding pipe while cutting.. very handy)
Step 3: Cut the Pipe
Here are the pipe lengths that we used
Qty | Lengths
4 | 39" (legs)
2 | 20-1/2" (side rungs)
2 | 44-1/2" (runners)
While cutting the pipe use a latex grip glove; it will make it much easier to hold. You might also have someone else hold the pipe for stability while cutting.
Step 4: Build the Bench/Shelf Top
Step 5: Assemble and Install Legs
Insert the leg into a 20-6 fitting that is a part of the top rectangle.
Slip-on the first MH50 onto your shelf mark and tighten the set screw.
Slip-on the second MH50 onto your second shelf mark and tighten the set screw.
Attach the 61-6 Flange the bottom of the leg and tighten the set screw.
Repeat this four times.
NOTE: your legs may initially be somewhat crooked. To rectify this tip the bench over on it's legs and adjust the how far some of the pipe is going into the fittings. You can do this by loosening and re-tightening the set screw.
Step 6: Cut and Install Shelves
We had Home Depot cut our 4x8 sheet into 4 pieces. We did the trimming ourselves with a circular saw. We took off about took off about 3-1/2" on the bottom shelves to make them fit.
NOTE ABOUT PICTURE: Yes we are a bunch of geeks who decided to where our cool Instructables T-shirt on the same day.. and no we didn't plan it.
Installing the Shelves
To install the shelves we simply placed the boards on the MH50s and screwed up through the whole with a screw (with a washer on it). If you want to make it easier (we did) you can tip the entire shelf on it's side and screw that way. Predrilling your holes will help the wood to keep from splitting.
Also helpful is to screw on the higher shelf before the lower (we learned this by experience).
**Make sure your screws are short enough that they don't poke through the top of your shelves.
Note that if you loosen the set screws of the MH50 you can move the shelf up and down.
Step 7: Install Top
Note: One cool thing we discovered after attaching the 105-6 to one side is that you can use these clips as hinges (see picture).
Step 8: Your Done!
There are probably some other things you could do to spiff this thing up. Tricia has a design for adding doors to the front. You might also consider finishing the wood if you're going to use this in a living space.
Have fun with it and tell us about your experience!
The guys a Simplified Building Concepts (Sam and Chris are in the pictures)