Hi Ian,
By laminated I mean that the planks of wood are all joined together standing on their edge, there are approx 15 planks held together with studding and glue. This process gives you a nice solid piece of wood from using just planks. The legs are made in the same way, with pallet "noggins" fitted on each side of the leg to give it support. The complete process is below;
1) Measure your planks to get the maximum useable lenth.
2) Drill a hole in each end of the planks and one in the middle. (End holes should be a couple of inches in from the end of the plank)
3) Through the 3 holes fit lenths of studding with a nut and large washer on the end.
4) Apply glue to the inside face of the plank and slide another plank down the studding so the glue is between the 2 planks.
5) Apply glue to the inside face of the second plank and slide another plank down the studding.....
6) Repeat process untill the bench top has reached the desired width.
Basically you are clamping the planks together on their edge using studding and gluing as you go.
When you have the right thickness you need to make a plank with three large holes in it to cover the ends of the studding that will be sticking out, when you have done this screw it to the bench top. You now screw a plain plank over this, this will give you a nice smooth plank on the outside so you cant see the studding. All screw heads should be countersunk and finnished off with dowels and glue.
The same process is used to make the legs, they are held on with coach screws fitted through the "noggins" that are screwed to the tops of the legs.
Finnish it by sanding untill smooth, apply a coat of varnish/white spirit mix (50/50) and let it soak in. Once dry rub it down and apply a coat of varnish. Give it 3 coats of varnish to give the wood depth, rubbibg it down with fine wet and dry paper between coats.
Job done! Now sit on your new shiney bench with a well earned cuppa!
Total coat is under 10 quid (coach screws, studding, etc,etc)
I hope all that makes sence, its a simple process but quite tricky to explain!
Regards,
Anthony.
