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How to make a concrete bench

Step 1.2   Cut the plywood, plastic, and assemble the bench form

concrete bench form assembly process

Cut a rectangular piece of ⅝" (15mm) thick plywood, 40" long x 22" wide (1000mm long x 550mm wide).

Also cut a rectangular piece of ⅛" (3mm) thick *plastic sheet, 40" long x 22" wide (1000mm long x 550mm wide).

*Note:   The plastic sheet is to make a smooth finish on the top of the bench. The end product of a concrete cast will be as smooth as the form. The plastic sheet can be any thickness, or you can disregard it altogether, in which case the finished product will be as smooth as the plywood form - which can still be an acceptable finish.

Lay the piece of plywood on a flat even surface.

Then lay the plastic sheet on top of the plywood sheet and the 'picture frame' on top of that.

Temporarily hold everything in place with clamps while you screw the all the pieces together.

Fix (glue and nail) strips of ½" (12mm) *angle fillet (f) around the inside perimeter of the bench form against the frame and the plastic sheet.

*Note:   Angle fillet is a triangular shaped strip of wood. Its purpose is to make a beveled-type edge around the top of the bench. You can use a different profiled piece of wood if you want something a bit more fanciful, or you can disregard it altogether, for a plainer look.

fixing a piece of angle fillet to the concrete mold

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