This is a super simple project that is perfect for the beginner woodworker. It's a classic furniture piece that fits in most design aesthetics. In this tutorial, I'm going to show you how to build a modern wooden bench with a woven fabric seat. Even if you've never woven a thing in your life, this project you can do. Also With basic 2x2 pine lumber, this project can be done for under $30. I got the idea for this project from a piece of furniture I saw in a magazine that was $800. This is a total look for less project. OK, Let's Get Dirty!
Step 1: Materials and Cut List
- 2x2 lumber (I used 8 - 1-1/2 in. x 1-1/2 in. x 3 ft. Poplar Hobby Boards. But this can be made with basic off the shelf pine lumber.)
- 2 1/2in screws (Pocket Screws or Spax Screws)
- Everbilt 1 in. Brown Nail-On Glide with Carpet (4-Pack)
- J-B Weld KwikWood 1 oz. Filler
- 36" (4)
- 17" (4) (legs)
- 12" (4) (legs)
- MAKITA 18-Volt LXT Lithium-Ion Sub-Compact Brushless Cordless Impact Driver Kit
- DEWALT 15-Amp Corded 12 in. Double-Bevel Sliding Compound Miter Saw
- Kreg Jig K5 Pocket-Hole System or a great starter pocket hole jig Kreg Jig Pocket Hole System
- DEWALT 20-Volt MAX Lithium-Ion Cordless Brushless 5 in. Random Orbit Sander
- HUSKY Soft Cap Gel Knee Pads (Protect your knees with these knee pads)
- Tape measure
- DEWALT DEWALT Carbon Fiber Staper
- Wiss 10 in. Shop Shear
- Hammer and or mallet
Step 2: The Legs
This bench is assembled using pocket holes. I found it be an easy way to hide the screws. Starting with the legs cut to size (2) 12in and (2) 14in. pieces per leg. I drilled the pocket holes and screwed together the pieces making 2 rectangular shaped legs.
Step 3: The Rails and Footrest
Next, It was time to attach the legs by attaching 2 of the 36in 2x2 boards to either side of the top of the legs.
Then Measure down 5.5in and install the footrest. It helps to mark the wood on all sides to ensure it's lined up.
Step 4: Sanding
Sand the Bench down and stain or paint it before moving on to the weaving. You wouldn't want sawdust or paint on the seat fabric. That's a pain to get out.
Step 5: Weaving
Now for the fun part. Weaving the seat takes a little time and patience. You want to make sure the polypropylene webbing is always tight and has no gaps. So starting going across the bench from back to front run the webbing and staple it under the bench frame. I stapled each piece of webbing multiple times to ensure it was secure. I also used a set of pliers to pull it tight before stapling.
Once the webbing is complete from back to front it's time to do the cross weaving from side to side. I found it easier to lay out and staple all the webbing pieces to the side before starting the weaving process to ensure I hade enough webbing to fully cover the bench. Then weaving the webbing, one by one up and over the cross weaving. I recommend doing one row at a time to ensure that it's straight and snug. You don't want to end up with weaving that is all bowed and curved when you're done. So take your time and go one row at a time. Secure it with staple and pull tight with a pair of pliers. I also found it easier with a 2nd pair of hands, someone to pull while I stapled.