You will need:
-(2) sheets of 5mm plywood or 6mm MDF/Supawood (for parts AG, N, O)
-(5) pieces of 50 x 100mm pine 2.5m long (for parts H, J, K, P, Q)
-(1) piece 20x50mm pine, 2.5m long (for parts L, M)
-Wood glue
-3mm drywall screws
-5mm drywall screws
-5mm finishing nails
-6mm screws and wall plugs
-Wood filler
-Acrylic primer
-Gloss enamel
-Cork tiles and contact adhesive
[Download Cutting List
PDF]
[Download Assembly Diagram
PDF]
Here's how:
Using a circular saw (or table saw), cut the plywood or MDF sheets into parts AG and N. Then cut the rabbets and dadoes on the right and left end panels (A, B) as shown. (All joinery cuts go on the inside faces of parts.) Also, cut a 20mm rabbet along the rear edge of the floorboard (C). Use a jigsaw to cut the radius on the front corners of the right end panel (A) and the wall bracket (N). Set the plywood panels aside, then cut the face-frame rails, stiles, support cleats, and other parts (H, J, K, L, M, P, Q) from the poplar stock.
Assemble Storage Bench
Arrange the short (P) and long (Q) floor cleats on a
flat surface and glue the mitred ends together. After
letting the glue at the joints set for a few minutes,
apply a bead on the top faces of the cleats, then set
the floorboard (C) on top of the cleats and position
for a 25mm overhang along the edges. Drill holes
along the perimeter (through the floorboard only),
then drive 3mm screws to secure the floorboard to
the cleats.
Use glue and finishing nails to attach the lower edge
of the right end panel (A) to the edge of the floorboard
as shown; make sure the front edges align. Repeat
to attach the left end panel (B). With both end panels
secured, attach the back panel (G) with glue and
nails. Then glue the base divider (D) in place as
shown (note the offset from centre) and secure it
with 5mm drywall screws driven up through the
floorboard and also through the back panel.
Apply glue inside the dadoes in the end panels,
then slide the step platform (E) into place. Drive finishing
nails through the ends and also through the platform into the
upper edge of the base divider. Then glue the upper divider (F) in place and attach it with screws driven through the back panel.
To complete the bench assembly, use glue and finishing nails to attach the face-frame rails (H) and stiles (J, K) to the front edges of the bench panels and dividers as shown. Use a hammer and a nail set to countersink all the finishing nails in the frame and other areas, then fill the holes with wood filler. Let dry, then sand flush with the surface. Use glue and screws to attach two support cleats (M): one to the top rail of the face frame (offset 20mm from the left end) and one on the inside face of the right end panel (A), 609mm from the floor.
Finish and Install
Cut the desk rails (L) to rough length, then cut and notch the wall bracket (N). Glue and screw the third support cleat (M) to the front of the wall bracket. Use a sanding block to ease all sharp corners and edges on these parts and on the storage bench assembly. Apply a coat of primer to all surfaces, followed by two coats of gloss or semigloss enamel. Let dry.
If necessary, prep the alcove area by removing the baseboard moulding where the bench will fit. (You may have to cut and reinstall some sections of the baseboard.) Fit the bench into place and secure using 6mm screws and plugs driven through the back panel (G). Test-fit one of the desk rails (L) against the wall, mark stud locations, then drill holes and screw the rail firmly to the wall. Similarly fasten the wall bracket (N) to the adjacent alcove end wall, then use glue and finishing nails to attach the front desk rail as shown.
Recheck the dimensions for the desktop/seat platform (O), then cut and test-fit that part in place. Adjust as necessary, then prime and paint. When dry, secure to the supports and the storage bench with finishing nails. Cut the cork tiles to fit and attach to the step platform.
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