- 3/4″ Sanded Plywood cut to length and width
- Fabric (a heavier material will have a longer life)
- Multi-Purpose Project Foam 1″
- Quilt Batting
- Oversized Buttons
- Upholstery Needle
- Staple Gun and Staples
- 10 x 1″ Phillips Flat Head Wood Screws
In Part One of this project, we covered the steps to order and assemble a table base kit as well as sanding and painting the base. In Part Two we will outline assembling the upholstered top and attaching to the top.
The plywood top for the bench should be cut to length and width. Most home improvement stores (such as Home Depot) will cut the plywood for you for a small fee if you don’t have a table saw. Otherwise, use your table saw to cut the plywood to length, then mark the desired location for the buttons. Use a measuring tape to ensure that each mark is evenly spaced and uniform, then drill a 1/8″ hole where you placed each mark.
Unroll the foam over the plywood and trim it to size. (If scissors aren’t doing the trick, try an exacto knife.) I used two layers of the 1″ foam for extra padding which made installing the buttons a little more challenging. Then unroll the quilting batting material on top of the foam and flip everything over to staple the batting under the bench top.
Pay attention to the folds on the corners, neatly tucking the batting then stapling it in place. This will keep everything smooth and clean cut.
Once the batting is stapled on all sides, lay the fabric along the long edge of the bench and staple a straight line done the length. Staple slightly farther in on the fabric than you did on the batting so that the staples don’t overlap. Then flip the bench over as shown to wrap the fabric around the top of the bench and back under on the other side. Staple the length of the other side then trim the excess fabric.
On the ends of the bench, pay special attention to the folds for the corner. You may want to add several staples as you pull sections tight and fold the end over and in. Once everything is neatly folded, tucked and stapled, trim off any excess fabric.
The last step is to combine the top and the bottom of the bench. Simply place the top upside down on a clean surface and set the bench frame on top of it. Screwing through fabric can be tricky if you don’t place sufficient pressure on the power drill while you tighten the screw. If possible, have someone help hold the frame in place centered on the upholstered top while you place a screw in each of the pocket holes of the base and drive it into the bench top. Use #10 x 1″ Phillips Flat Head Wood Screws, and be careful not to over tighten the screw. Tighten the screws snug at each corner of the bench then install the remaining screws.