1. Make the bench frame
On the bearers mark the trimmers 100mm from the ends and at the centre, drilling 4mm clearance holes, securing with 75mm screws. Position the decking with 10mm overhang, with short boards at the ends, securing from end to end.
Having drilled the pilot holes for the slats, consider painting them before assembly. Hang them up to dry, using the pilot holes as attachment points.
2. Finish posts and add pipe
Chamfer the top of the posts, sanding with 80-grit abrasive paper. On the foot posts mark 100mm from the top, wrapping cardboard around to mark a square line to drill a hole for the galvanised pipe, securing it with cuphead bolts.
3. Attach the foot posts
Drill 10mm holes, 50mm from the end of the bearers, and position the posts over the bench with a 175mm space between the bed and the pipe. Drill through the bearers and the posts, assembling with 175mm bolts, washers and lock nut.
4. Fit bench to head posts
Lift the bench until level, using a spirit level to check. Mark the base of the bearers on the inside of the posts, clamp and drill four holes 75mm apart through the posts. Slide adjustable bolts through to support the bench.
(measurements in mm)
||1200 x 100
||2300 x 90 x 45
||360 x 90 x 45
||470 x 90 x 20
||450 x 90 x 20
||600 x 25
For each station use 125 x 10mm galvanised cuphead bolts to anchor the pipe to the posts, and 175 x 10mm galvanised cuphead bolts to secure the bearers to the posts of the sit-up bench.
Fit the bolts with 10mm washers, securing using galvanised lock nuts.
WEATHERPROOFING Avoid rust by using galvanised or treated pine fasteners for the decking, and give all the timber two coats of exterior paint to seal.
TIP We used Dulux Primer for New Wood, followed by Dulux in Plush Velvet 2.
All the products required for this project are available from Builders Warehouse.