Simple Joinery Long Bench

Ian Anderson

Simple Joinery Cotton Strap Bench by Ian Anderson
Simple Joinery Cotton Strap Bench by Ian Anderson
Simple Joinery Long Bench

Design and photography by Ian Anderson
Published in Spring 2021

Because of the efficient use of wood in this design, costs to produce it are rather low. It’s generous 73in length can be made longer or shorter by changing a quick wood measurement during its production. Working with hardwood can be quite tough, though necessary in the case of this design, but poplar hardwood (or other equivalent wood on the Janka hardness test scale, like cherry) is just soft enough where cutting, sanding, and stapling are easy.

Simple Joinery Cotton Strap Bench by Ian Anderson
Simple Joinery Cotton Strap Bench by Ian Anderson
Assembly
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1     Saw these lengths of wood: 4 pieces 71in (180cm) long, 8 pieces 17.5in (44cm) long, 2 pieces 22in (56cm) long.
1     Saw these lengths of wood: 4 pieces 71in (180cm) long, 8 pieces 17.5in (44cm) long, 2 pieces 22in (56cm) long.
2     Saw each of the two 22in (56cm) long pieces in half at a 45 degree angle. Make sure all resulting pieces are exactly the same length.
2     Saw each of the two 22in (56cm) long pieces in half at a 45 degree angle. Make sure all resulting pieces are exactly the same length.
3     A couple of inches from the end of a 71in (180cm) long piece, make a mark 3/8in (1cm) from the long edge.
3     A couple of inches from the end of a 71in (180cm) long piece, make a mark 3/8in (1cm) from the long edge.
4     Drill a small pilot hole in that mark. Then with a 1/4in drill bit, mark about 1/2in (1.5cm) up the bit with a piece of tape.
4     Drill a small pilot hole in that mark. Then with a 1/4in drill bit, mark about 1/2in (1.5cm) up the bit with a piece of tape.
5     In the spot of the pilot hole, drill a hole up to the mark made in step 4.
5     In the spot of the pilot hole, drill a hole up to the mark made in step 4.
6     Add glue to the hole, and insert a dowel pin as far in as possible. Wipe away excess glue.
6     Add glue to the hole, and insert a dowel pin as far in as possible. Wipe away excess glue.
7     Repeat steps 3-6 at the other end of the piece of wood, and at points about 12in (30cm) apart along the piece of wood.
7     Repeat steps 3-6 at the other end of the piece of wood, and at points about 12in (30cm) apart along the piece of wood.
8     Along the spine of another 71in (180cm) long piece of wood, mark where the dowels lie.
8     Along the spine of another 71in (180cm) long piece of wood, mark where the dowels lie.
9     As in step 5, drill holes along the center of the spine of the new piece of wood where the dowels line up.
9     As in step 5, drill holes along the center of the spine of the new piece of wood where the dowels line up.
10     Glue along the spine and inside of the holes.
10     Glue along the spine and inside of the holes.
11     Join the two pieces of wood, pushing the dowels inside of the holes. Wipe away excess glue. Repeat steps 3-11 with the remaining two 71in (180cm) long pieces of wood.
11     Join the two pieces of wood, pushing the dowels inside of the holes. Wipe away excess glue. Repeat steps 3-11 with the remaining two 71in (180cm) long pieces of wood.
12     As in step 5-6, drill 4 holes and glue in dowels at both ends of each piece from step 11.
12     As in step 5-6, drill 4 holes and glue in dowels at both ends of each piece from step 11.
13     Positioning each piece from step 11 slightly inset from the edge of a 17.5in (44cm) long piece of wood, mark where the dowels touch the wood.
13     Positioning each piece from step 11 slightly inset from the edge of a 17.5in (44cm) long piece of wood, mark where the dowels touch the wood.
14     Drill holes for the dowels in the 17.5in (44cm) long piece of wood, then glue and join the pieces from step 13.
14     Drill holes for the dowels in the 17.5in (44cm) long piece of wood, then glue and join the pieces from step 13.
15     Repeat step 13-14 on the other end.
15     Repeat step 13-14 on the other end.
16     Glue and insert 2 dowel pins into both ends of a 17.5in (44cm) long piece.
16     Glue and insert 2 dowel pins into both ends of a 17.5in (44cm) long piece.
17     Align the end of the piece from step 16 on the center, and 1 width of wood from the end of a new 17.5in (44cm) long piece of wood. Mark where the dowel pins lie.
17     Align the end of the piece from step 16 on the center, and 1 width of wood from the end of a new 17.5in (44cm) long piece of wood. Mark where the dowel pins lie.
18     On each end of the piece from step 16, join a 17.5in (44cm) long piece at the points marked in step 17. Place on flat surface to dry.
18     On each end of the piece from step 16, join a 17.5in (44cm) long piece at the points marked in step 17. Place on flat surface to dry.
19     On two pieces from step 2, glue in dowel pins as pictured.
19     On two pieces from step 2, glue in dowel pins as pictured.
20     Mark 8in (20cm) from where the two pieces of wood from step 18 meet each other, and draw a 45 degree line away from that point.
20     Mark 8in (20cm) from where the two pieces of wood from step 18 meet each other, and draw a 45 degree line away from that point.
21     Align your dowel pins from step 19 along that line.
21     Align your dowel pins from step 19 along that line.
22     Drill, glue and join the pieces together. The piece from step 19 should not hang off of the edge of the piece below it (the piece below it in the photo). Repeat with the other piece from step 19 (see next photo for result).
22     Drill, glue and join the pieces together. The piece from step 19 should not hang off of the edge of the piece below it (the piece below it in the photo). Repeat with the other piece from step 19 (see next photo for result).
23     Repeat steps 16-22. Now you have your completed bench legs.
23     Repeat steps 16-22. Now you have your completed bench legs.
24     On the underside of the piece completed in step 15, mark 10.5in (27cm) from each end.
24     On the underside of the piece completed in step 15, mark 10.5in (27cm) from each end.
25     Line that mark up with the center of a piece completed in step 23, and drill 4 holes for your screws.
25     Line that mark up with the center of a piece completed in step 23, and drill 4 holes for your screws.
26     Screw in 4 screws, as photographed.
26     Screw in 4 screws, as photographed.
27     With 2 screws, drill and screw in the point where the 45 degree piece of the leg meets the seat frame. Secure the 3 other legs with the seat frame as in steps 25-27.
27     With 2 screws, drill and screw in the point where the 45 degree piece of the leg meets the seat frame. Secure the 3 other legs with the seat frame as in steps 25-27.
28     Sand down the hard edges of the wood, especially along the seat frame, where the webbing will lie.
28     Sand down the hard edges of the wood, especially along the seat frame, where the webbing will lie.
29     Disassemble and apply two coats of varnish or paint.
29     Disassemble and apply two coats of varnish or paint.
30     At one end of the seat frame, fold a piece of webbing under and staple it down with 6 staples.
30     At one end of the seat frame, fold a piece of webbing under and staple it down with 6 staples.
31     Stretch the webbing over the frame as tight as possible by pulling with one hand and cinching over the edge of the frame with the other. Hold the webbing tight with one hand, and apply 3 staples with the other hand.
31     Stretch the webbing over the frame as tight as possible by pulling with one hand and cinching over the edge of the frame with the other. Hold the webbing tight with one hand, and apply 3 staples with the other hand.
32     Cut the webbing about 1in (3cm) from your 3 staples, tuck the excess webbing under, and apply 3 more staples on top.
32     Cut the webbing about 1in (3cm) from your 3 staples, tuck the excess webbing under, and apply 3 more staples on top.
33     Repeat steps 30-32 with 5 or 6 more straps, equally spaced.
33     Repeat steps 30-32 with 5 or 6 more straps, equally spaced.
34     As in steps 30-32 apply and weave in webbing along the width of the seat, spaced about 3/4in (2cm) apart. Stop about where the legs screw into the seat frame.
34     As in steps 30-32 apply and weave in webbing along the width of the seat, spaced about 3/4in (2cm) apart. Stop about where the legs screw into the seat frame.
35     Attach the seat frame to the legs, and continue applying horizontal webbing until the seat is done. Make sure to measure out your spacing in advance.
35     Attach the seat frame to the legs, and continue applying horizontal webbing until the seat is done. Make sure to measure out your spacing in advance.
Index
Parts
Smooth Planed Poplar Wood, 1in x 3in (20.5mm x 70mm)
*Any popular hardwood can be used, like Poplar, Birch, Beech, Cherry, and Oak. Softer hardwoods like Cherry and Poplar are recommended. Metric measurements above are actual, not nominal.
 
Quantity required: 4 pieces 71in (180cm) long, 8 pieces 17.5in (44cm) long, 2 pieces 22in (56cm) long
Heavyweight Cotton Webbing, 2in (50mm) width, 2mm thick
Quantity required: 32 yards (29 meters)
1/4in Dowel Pins
Quantity required: 50
Satin Clear Acrylic Varnish (or paint)
Quantity required: 1/4 Quart
Flat Head Wood Screws, #6 x 1-1/2in (4 x 35mm)
 
Quantity required: 24
Tools
Hand Saw
Power Drill
Drill Bits
Ruler or Tape Measure
Screwdriver
Wood Glue
Sandpaper, 180 Grit
Heavy Duty Upholstery Staple Gun w/ Staples
Help Each Other

4 thoughts on “Simple Joinery Long Bench”

  1. Where did you buy the heavyweight cotton? The ocre color looks great, and I’d like to replicate it. But I’m hesitant to buy the yellow strap linked via eBay above since that yellow looks more harsh/bright. (I’ve really enjoyed making three of the chair designs here with my young boys-thanks for the great site!!)

    Reply

    1. We’re so glad you’re making use of the instructions! We would love to see how they are turning out – feel free to send some images our way!

      The yellow strap was bought from this supplier, so it should look the same in-person. There is a chance some things have changed regarding their production though, so we would recommend buying a sample first. There are a variety of other strap suppliers on etsy that offer 2″ cotton straps, but I don’t think they will be quite as thick as this one.

      *One construction note on the bench: If this will go through heavy use, we recommend reinforcing the mid section with an extra 16.75″ long 1×3 across the underside before adding the straps. This will help with any bowing caused by the torque of the straps.

      Reply

  2. If I wanted to do a solid wood bench instead of cotton webbing, how would you recommend doing that? Thanks for your help!

    Reply

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