Procrastination Ranch: Weekend Project - Building my Leopold Bench

This weekend I was at the local hardware store early in the morning and was able to get some discounted lumber for Really cheap and most of it was surprisingly straight! Once I got it all home I decided I had everything I needed to build a Leopold Bench - especially since we are in desperate need of seating in our yard. The best part about a Leopold Bench is they are incredibly easy to build, as the wise man Michael Scott once said - keep it simple, stupid.

Untreated Lumber:

(1) - 2" x 8" x 10' - for Legs
(1) - 2" x 12" x 36" - for Seat
(1) - 2" x 12" x 39" - for Back

Hardware:

(6) - 3/8" Carriage Bolts 3 1/2" Long
(6) - 3/8" Washers
(6) - 3/8" Nuts
(10) - Deck Screws 3" Long

Tools:

Electric Drill
Circular Saw (or hand saw)
Measuring Tape
Pencil
Speed Square
3/8" Spade Bit
1/8" Drill Bit (or Counter Sink Bit)
Phillips Bit
   Optional:
      Sawhorse
      Clamps
      Sandpaper
      Stain/Paint

To the right is a list of the lumber, hardware and tools I used to build the bench.

Since I do not have a sawhorse (I plan on building one some day) I used a couple pallets instead, also I do not have clamps wide enough for this project so I made do without - however, I would recommend using clamps if you have them.

Here are the steps I took (photos are below):

First the legs - I placed the 2" x 8" board on a pallet and made pencil marks at 33, 66, 85 and 102 inches.
Then I used a speed square to make a 60 degree angle at each of the 4 marks and from the top corner of the board so all ends are cut at a 60 degree angle. (A) To make a 60 deg. angle with the speed square, use the 30 deg. mark since the square is already at a 90 deg. angle. Cut the board with a circular or hand saw. (B)
Assemble the legs - Since I used pallets as a work bench and I needed a good straight edge as a guide, I decided to screw a couple straight boards to the bottom of the pallet so I could rest the 'feet' of the bench against the flat surface. (C)
Since I forgot to buy bigger clamps I stood on the boards while I drilled 3 holes through the legs with a 3/8" spade bit. I made sure to set the boards in the right direction before drilling, and marked left/right for easy assembly. The shorter boards should be on the insides of the bench to hold up the seat. (D) (E)
After drilling the boards, I pushed the carriage bolts through both boards and tightened down with some 3/8" washers and nuts making sure the head of the bolts are on the outside of the seat. I used zinc plated hardware because it is what I had available however, if you are going to buy new hardware and have access to it - I would purchase hot-dip galvanized steel hardware since it will hold up to the weather much better. (F) (G)
Build the seat - I set the 2x12 board on a pallet, measured 36" and made a straight cut with a rotary saw. Then, with help from the kids we set the 2x12 on the two previously assembled leg pieces. Once we had the seat lined up, I set 6 deck screw through the top of the seat into the short leg pieces - 3 on each side. (H)
Build the back rest - I made a cut about 3" in to the tops of the long legs using a speed square so the back would be vertical. (I)
Then I cut a 2x6 board at 39" and attached it with 4 deck screws - 2 on each side. The piece I used for the back was older wood and is a bit rough but once I sand and stain, it will all look the same. (J)