In this detailed guide, Matt from MWA Woodworks shares his step-by-step process for creating durable outdoor benches using red cedar. With a focus on quality materials and construction techniques, this project is perfect for anyone looking to enhance their outdoor space.
Materials and Tools Needed
- 6×6 red cedar beams
- Total Boat epoxy resin and hardener
- Total Boat Gleam 2 marine varnish
- Wood screws
- Wood glue
- Wood sander (60 grit and 150 grit discs)
- Planer
- Jointer
- Band saw
- Miter saw
- Track saw
- Drill press
- Marking knife
- Tack cloth
- Foam brush
Step 1: Milling the Cedar Beams
The project begins with rough-sawn 6×6 red cedar beams. The first step is to mill them square. Matt starts by flattening one face on the jointer, then flips the beam to flatten the opposite face. This ensures both faces are square to one another, which is crucial for the glue-up process.
Step 2: Planing the Beams
Next, Matt moves to the planer to flatten the remaining two faces of the beams. By placing the joined faces down, he makes the opposing faces parallel. After a few passes, all four sides are flat and squared up.
Step 3: Cutting the Legs
Using the band saw, Matt cuts the legs for the benches from the same beams. He emphasizes how smoothly the band saw cuts through the cedar, leaving clean edges. After resawing, he sends the legs through the planer to remove any mill marks and achieve final dimensions.
Step 4: Trimming to Final Length
Before cutting joinery, the beams need to be trimmed to their final length at the miter saw. Since the beams are too thick for a single pass on the 12-inch slider, Matt finishes the cut with a handsaw.
Step 5: Preparing for Assembly
For assembly, Matt chooses epoxy as the adhesive due to its water-resistant properties. He combines the resin with hardener in a 2:1 ratio and mixes thoroughly. An even coat is applied to the glue joints of the three beams that will form the bench seat.
Step 6: Clamping and Planing
After applying clamping pressure, Matt runs the glued-up bench seat through the planer to clean up the surfaces and flatten everything again. This step is crucial for ensuring a smooth finish.
Step 7: Squaring the Edges
Matt squares up the edges at the jointer, ensuring that the legs will fit snugly into the sides of the bench. This step is essential to avoid a wobbly bench.
Step 8: Cutting Notches for the Legs
Using a marking knife, Matt lays out the notches to be cut in the bench top. He utilizes a table saw with a dado stack to efficiently hog out the material, creating clean notches that fit the legs perfectly.
Step 9: Fitting the Legs
After creating the notches in the bench top, Matt cuts matching notches in the legs. He reinforces the joints with screws, which also serve as clamps while the epoxy cures.
Step 10: Plugging Screw Holes
To cover the screw holes, Matt uses a plug cutting bit on the drill press, which makes the process satisfying and efficient. He applies epoxy to the plugs and sands them flush once dried.
Step 11: Sanding the Bench
Matt begins sanding the bench using a 60 grit disc to remove mill marks and glue stains. He finishes with a 150 grit to prepare the surface for finishing. This is crucial for achieving a smooth surface that will hold the finish well.
Step 12: Applying Epoxy Sealer
For protection, Matt applies Total Boat’s epoxy sealer with a roller. This thin coat penetrates deeply into the cedar, enhancing its durability against outdoor elements.
Step 13: Sanding and Varnishing
After the sealer cures, Matt sands the bench with 320 grit sandpaper and wipes it down with a tack cloth. He then applies Total Boat’s Gleam 2 marine varnish, starting with three coats of high gloss followed by two coats of flat to achieve the desired sheen.
Final Thoughts
Matt is pleased with the final product, noting how the color of the cedar pops and how well-protected the benches are from the elements. This project not only enhances outdoor spaces but also provides a sturdy seating option for years to come.
