UPDATE: This bench was featured in an article by Amanda Kwan of the Associated Press in August of 2009. I completely forgot to post an update until I was in IKEA this weekend! A photo of the painted bench has also been included.
http://www.knoxnews.com/news/2009/aug/03/no-headline---080309craft/
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Signing UpStep 1Buy the materials
IKEA Chair - $20
Home Depot Super-strip $2.97 (2)
Home Depot Laminated Pine Panel 1/2" X 18" X 48" $12
2" wood screws (4)
The remaining hardware is included with the chair.
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The best bet might be going to an actual lumber yard and having the boards planed to the thickness you want.
1. add a center leg set by cutting a third chair off just above the mortise for the seat. or
2. Make the crossrails beefier and ensure that their are supports running widthwise (front to back) not just lengthwise.
My bench if memory serves is just under 4' (122cm). That being said, at Christmas it held two full sized adults with a combined weight of 32 Stone, not that I wasn't waiting to hear a crash. Good luck, my sister gets a great deal of use out of it.
Tenons scare off a lot of people. Once you get the system down, they are easy no matter what type of tools you're using.
Good luck!
http://www.knoxnews.com/news/2009/aug/03/no-headline---080309craft/