How to repair and protect all types of outdoor furniture
To make this project easier, we had the timber cut to size at Bunnings.
Cut the formply to the following measurements:
Cut the 90mm x 19mm Merbau decking to the following lengths:
Make a four-sided box from the formply, starting with the sides, and front and back pieces. Use corner clamps to hold the corners steady while drilling. Pre-drill with a countersink bit and fix the box together with 40mm screws. Then insert the base, pre-drill and screw.
Measure and mark where you want the three hinges. Mark for the holes. Pre-drill and use the 40mm screws to attach the hinges to the box. Now flip the box onto its side, pre-drill and screw the hinges to the lid. Use a piece of cladding to lift the box off the workbench.
When attaching cladding to the back, start from the base. The final decking board will need to be rip-cut to make enough room for the hinges and the lid opening. Measure and mark to rip-cut the board. Your measurements will depend on the size of your bench seat. Clamp the timber to the workbench before cutting. Rip the cladding to size with the circular saw. Fix it into place.
To fix the decking to the lid, lay it out, starting from the back. Use the nail gun to fix the decking to the lid. Leave an overhang at the front to act as a handle.
Because the overhanging lip at the front of the bench seat doubles as a handle, lift up the lid and use the 30mm screws to secure the decking from the underside of the lid.
If needed, sand the bench seat with 120 grit sandpaper. You can leave the storage bench seat to weather or once the tannins have leeched, give it a varnish with something like Cabothane clear. Apply as many coats as needed. Leave to dry between coats.
You can put your bench seat wherever you like in the garden, fill it with gardening tools, cushions or anything you want to keep handy. Now sit back, relax and admire your good work.