DIY Network

Inside Job: Bench Chest DIY provides a behind-the-scenes look at how Carter Oosterhouse created the bench chest for the HGTV show Carter Can. From "The Inside Job" episode DISJ-102

The completed bench chest

A bench chest is a nice addition to almost any room. This decorative furniture accessory serves two purposes: seating and storage space.

This particular piece is fairly easy to build and, once finished, will add both functional storage space and a touch of style to your home.

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Materials:

(8) 3/4 inch legs (1 foot, 4-1/4 inches x 3-1/2 inches)
(4) 3/4 inch horizontal side beams (12 inches x 3-1/2 inches)
(4) 3/4 inch horizontal front/back beams (3 feet, 1-1/2 inches x 3-1/2 inches)
(2) 3/4 inch front/back spacers (6-1/4 x 3-1/2 inches)
(2) 3/4 inch bottom side rods (1 foot, 6-1/2 inches x 3/4 inch)
(2) 3/4 inch front/back ledgers (3 feet, 5-1/2 inches x 3/4 inch)
(1) 3/4 inch plywood bench bottom (3 feet 6-3/4 inches x 16-1/2
(2) 3/4 inch birch siding for bench sides (1 foot 6-1/2 inches x 11-1/2 inches)
(2) 3/4 inch birch siding for bench front and back (3 feet, 6 inches x 11-1/2 inches)
(1) 1-1/2 inch pine plywood lid (3 feet, 10 inches x 1 foot, 7 inches)
(1) 1-1/2 inch pine plywood lid (3 feet, 10 inches x 2 inches)
(1) piano hinge, 3 feet, 10 inches (comes with screws)
1-1/4" screws
1-1/4" nails

Tools:

pocket hole kit
pocket hole bit
square drive coarse thread pocket screws
drywall and square drive
carpenters glue
nail gun
countersink drill bit

Figure A

Steps:

1. To begin making your bench, you'll need to do some prep work. Set the depth collar so that your drill stops 2mm from the jig base. Take the horizontal side beams and clamp them vertically into the pocket jig. On the same side of the beam, drill two holes evenly on each end (figure A). Since the pocket jig has three holes on it, just drill through the two end holes. Repeat this step on the beams for the front and back, as well as the spacers.

2. Now that you've drilled all the holes you'll need, it is time to start putting the bench frame together. Begin by screwing the side beams to the legs with the square drive coarse threaded pocket screws (figure B) . Make sure you are screwing through the holes on the side beams, not the holes on the legs. Place the lower beam for each side two-inches from the bottom. Repeat this step for the front and back frames as well, remembering to add the spacer between the upper and lower beams.

3. Take the side bench frame and place one of the legs horizontally into the pocket jig. Drill four holes evenly down the side. Repeat on the opposite leg. You'll use these holes to attach the frame of the bench together (figure C).

Figure B

Figure C

4. Now that you have a frame piece for each side of the bench and all the holes are drilled, it's time to put them together. When attaching each section, use a clamp to hold the pieces in place. Attach each side by screwing through the holes created (figure D). Do this all the way around until the bench frame becomes one unit.

5. With the framing complete, turn the bench over and add quarter-inch ledgers all the way around the inside bottom of bench. Once the ledgers are placed, use a countersink drill bit to drill holes evenly across the ledgers (figure E). Go back and screw 1-1/4 inch screws to attach.

Figure D

Figure E

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