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Step-by-step build — 27 steps. Also available as a print sheet.
Please be sure to read through complete instructions before you begin any work on this project. Also keep in mind that plywood may be slightly thinner than its stated thickness. So some minor adjustments to plans may be required. Another good practice to use is, after the original carcass is assembled, cut to fit all additional pieces that are needed. While every effort was made to make the cut dimensions listed as accurate as possible, cutting to fit will adjust for any slight discrepancies in your assembly.
Cut the bench side panels, door panels, and back panel from the 1/4" oak plywood sheet. Use 100 - 150 grit sandpaper to smooth the parts.
Using the dimensions in the following diagram cut the pieces required for assembly. Please note that if you decide to cut the top from boards it will require glueing up. The top can be made from either 3/4" Plywood or one of the 1X8X96" boards. THE CUT PLANS AND MATERIALS LIST SHOW BOTH...DO NOT CUT BOTH...CHOOSE ONE OR THE OTHER. If edge glued, the rough top will be larger than the finished top. That is OK as we will eventually cut it to size. Use 100 - 150 grit sandpaper. If you cut the top from 3/4" plywood you will need one fewer 1X8X96" board.
If you used Plywood for the Bench Top skip this step. Edge glue the boards labeled 1/2 of top in step 4. If you are uncomfortable doing this I have attached one site with good information on the process. Please feel free to look at other sites. I normally use my Jet jointer to square and flatten the edges. Lay out the boards to provide the best looking grain. Use multiple clamps to bring the boards together. Make sure that the edges fit together well. Release the clamps and spread Titebond I wood glue along all of the edges to be joined. Avoid using excess glue. Realign the boards and clamp snugly. A picture of a typical clamp up follows.
Use a Freud (99-036) Adjustable Tongue and Groove Bit set mounted in a Kreg router table to cut the tongues and grooves. The groove cutter bit is adjusted to cut 1/4" X 3/8" grooves in the center of the inside edges of the outer door stiles as well as in both edges of the inner stiles. Then use the tongue cutter bit adjusted to cut 1/4" X 3/8" tongues on both ends of the inner stiles. Alternatively the grooves and tongues can be cut on a table saw.
Use a Freud (99-036) Adjustable Tongue and Groove Bit set mounted in a Kreg router table to cut the tongues and grooves in the four rails. Use the groove cutter bit adjusted to cut 1/4" X 3/8" grooves in the center of the rails inside edges. Then use the tongue cutter bit adjusted to cut 1/4" X 3/8" tongues on both ends of the rails. Alternatively the grooves and tongues can be cut on a table saw.
Use a Freud (99-036) Adjustable Tongue and Groove Bit set mounted in a Kreg router table to cut the tongues and grooves. The groove cutter bit is adjusted to cut 1/4" X 3/8" grooves in the center of the inside edges of the front and rear stiles as well as in both edges of the center stile. Use the tongue cutter bit adjusted to cut 1/4" X 3/8" tongues on both ends of the center stiles. Alternatively the grooves and tongues can be cut on a table saw. Now mark the legs on the front and back stiles. Using a band saw or jig saw cut the legs. Use Kreg Pocket Hole Jig to drill holes in the front rails as shown. Be careful there is a left and right side.
Use a Freud (99-036) Adjustable Tongue and Groove Bit set mounted in a Kreg router table to cut the tongues and grooves in the four rails. Use the groove cutter bit adjusted to cut 1/4" X 3/8" grooves in the center of the rails inside edges. Then use the tongue cutter bit adjusted to cut 1/4" X 3/8" tongues on both ends of the rails. Alternatively the grooves and tongues can be cut on a table saw.
Use a Freud (99-036) Adjustable Tongue and Groove Bit set mounted in a Kreg router table to cut grooves. The groove cutter bit is adjusted to cut 1/4" X 3/8" grooves in the center of the inside edges of the back stiles. Mark the leg cuts on the two rear stiles. Using a band saw or jig saw cut the legs. Keep in mind that you will be cutting a left and right side...so keep the best looking side out on both. Use Kreg Pocket Hole Jig to drill holes in the back stiles as shown. Be careful there is a left and right side.
Use a Freud (99-036) Adjustable Tongue and Groove Bit set mounted in a Kreg router table to cut the tongues and grooves in the two rails. Use the groove cutter bit adjusted to cut 1/4" X 3/8" grooves in the center of the rails inside edges. Then use the tongue cutter bit adjusted to cut 1/4" X 3/8" tongues on both ends of the rails. Alternatively the grooves and tongues can be cut on a table saw.
Using the Kreg pocket jig, drill pocket holes in the bottom as shown.
Carefully measure and mark the distance from the bottom of the leg to the lower edge of the bench bottom. Attach the bench bottom using wood glue and 1 1/4" Kreg fine pocket screws to the back and sides.
Using pocket screws and wood glue attach the front frame to the sides and bottom.
Attach the two hinge supports to the left and right side front stiles. Use wood glue and 1 1/4" brad nails.
On the hinge supports inside the cabinet mark the position of the hinge mounting plates. Pre drill small holes for the screws that hold the mounting plates. Attach mounting plates per the hinge manufacturers instructions. After the doors are mounted use the various hinge adjustments to properly set the side to side and top to bottom clearances on the doors.
Use a round over bit mounted in a router table to round over the 1" front edge. Using wood glue and 1 1/4" brad nails attach the front edge to the bench top and front stiles. The front edge should be flush with the top and the left/right sides.