Bench Seat Materials:
Two old panel doors
2x6 lumber
2x4 lumber
3/4-inch plywood
1/2x1-inch lumber
Eight sofa legs
3/8-inch dowel or ceiling flanges and coach screws (optional)
3/4x1/4-inch pine molding strips
Decorative composition molding rosettes
Wood screws: No 8x3 and No 8x1-1/2 inches
3/4-inch dado blade
Router and straight bit
Biscuits
Plate joiner
Wood glue Wood putty
Wire brads
Sandpaper


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Bench Seat Directions:
1. Trim one door for sofa back A to center the panels. Cut two panels from the second door for sofa arms B. Cut seat-frame pieces C and D from 2x6 lumber long enough to accommodate sofa back A and arms B.

2. Rout a 3/8-inch-wide and 3/4-inch-deep rabbet on the top inside edges of C and D, and miter each end. Cut slots for biscuits at each miter. Use glue and biscuits to assemble seat frame.
           
3. Cut two support rails E from 2x4s; attach to C at equal distances from sides of frame D with glue and No 8x3-inch wood screws; check for square.
           
4. Cut and miter frame-base pieces F and G from 2x4 lumber the same lengths as C and D. Cut slots for biscuits, glue and assemble, and attach to the bottom of the seat frame with No. 8x3-inch wood screws. Cut 3/4-inch plywood seat panel H to fit flush inside the rabbet, and attach with No. 8x1 1/2-inch wood screws.
           
5. Mark back and sides of seat frame along top edge for 1/2x1/2-inch slots. Attach edge guide to router, insert straight bit, and set it to 1/2 inch deep and 3/8 inch from the outside edge of the seat frame; cut corresponding slots in the back and arms. Cut splines I from 1/2x1-inch material to fit. Use glue and splines to attach sofa back and arms to seat frame. Predrill for No 8x3-inch wood screws; countersink from the back to secure arms to back. Clamp and set aside to cure.
           
6. Mark placement of legs J on bottom of frame base so legs will be flush with outside edge of frame. Drill holes for 3/8-inch dowels in top center of each leg and in bottom of frame base. Attach legs with glue and dowels.
           
7. Glue and use brads to attach 3/4x1/4-inch molding along edges of seat frame. Add vertical lengths of molding to frame each rosette. Glue rosettes to frame.
           
8. Fill any holes with wood putty. Sand all surfaces, wipe away dust, and apply two coats of primer, drying and sanding between coats.

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