How to make a boot bench

Making the boot box frame

On the previous page are the plans, the parts list and a parts description.
Refer to that page for all dimensions, wood sizes and part placements.

Step 1: 

1a.   Cut the eight front and rear rails [c] and the eight side rails [d] to length.
Refer to the parts list for measurements.

1b.   Cut the front legs [a] to length.

1c.   The back legs need to be shaped.
First cut two pieces of 90mm x 45mm (1 1/2″ x 3 1/2″) wood [b] to a length of 850mm (34″). Lay both pieces on a couple of sawhorses and mark the shape of the back legs using the plans for reference.
Then cut out the shape. This can be done using a circular power saw and a jig-saw.

Step 2: 

Lay the two front legs [a] on a work platform and mark where the front rails [c] are to go. Refer to the plans for the measurements.

The front rails should be set out in hit-and-miss fashion. That means that the gap between the rails should be the same as the rails’ width.
Start the top front rail 400mm (16″) up from the bottom of each leg.

Nail the front rails [c] to the front legs [a] using 50mm (2″) galvanized nails. First pre-drill the nail holes in the front rails [c] to avoid spitting. Once nailed, set (punch) the heads of the nails into the wood.

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Step 3: 

Lay the two rear legs [b] on a work platform and mark where the rear rails [c] are to go. Refer to the plans for measurements.

The rear rails should be set out in hit-and-miss fashion. That means that the gap between the rails should be the same as the rails’ width.
Start the top rear rail 400mm (16″) up from the bottom of each leg.

Nail the rear rails [c] to the rear legs [b] using 50mm (2″) galvanized nails. First pre-drill the nail holes in the rear rails [c] to avoid spitting. Once nailed, set (punch) the heads of the nails into the wood.

Step 4: 

Once the front rails are fixed to the front legs and the rear rails are fixed to the rear legs, then balance both sections on edge (see picture).
Thread the side rails [d] in between the front and rear rails [c]and nail them to the legs.

Step 5: 

Stand the frame the right way up on a work platform.

Now it’s starting to take shape.

Step 6: 

Cut the two front and rear plywood panels [e]. Refer to the plans for dimensions. Ensure that they will fit inside the boot bench frame.

Then nail a strip of wood [f] to the bottom of each panel.

Make the strips of wood [f] approximately 25mm (1″) shorter than the plywood each end.

The purpose of the strips of wood are to support the base boards [o].