DIY: Bench from bi-fold doors

Bench Made From Re-purposed Bi-fold Doors
Tools Needed: -

  • Circular saw or table saw
  • Sander
  • Drill w/countersink bit and drill tip to match fasteners
  • 3" stainless steel wood screws ( No. 10) and wood glue
  • 12-16, 1 1/2" stainless steel wood screws (for reinforcement)
  • Sandpaper- 120 Grit
  • Tape measure
  • Pencil
  • Straight edge
  • 2 1/2 wood bi-fold doors
  • 4 2x2 posts

As always work in a well-ventilated area, use a strong stable work surface, don’t hurry and always wear safety glasses!

Process:

  1. Select some sturdy bi-fold doors…..solid wood work the best of course! I used 2-1/2 doors for this project.
  2. One door provided a side panel and a part of the seat, repeat twice. I used an additional 1/2 door for the seat back. Louvered, paneled, and solid face doors will all work fine, and will add some creative differences.
  3. Decide on the width and height of your bench
  4. Measure and layout your cuts on the doors you’ve chosen to get your desired design, - …. then measure again :)
  5. Take your time and cut all pieces as efficiently as possible to maximize the best use of your materials. Save the extra pieces for your next project!
  6. I used a circular saw and table saw to do all the cuts necessary for this project. All of them were simple straight cuts,
  7. Sand all your cut edges that may come in contact with hands and seats :)
  8. Use wood screws and wood glue (if desired) to assemble. I used 3” x 10 stainless steel screws on this project to avoid corrosion and rot. I also utilized a countersink bit to make sure all screw heads were buried and out of harm’s way.
  9. Fasten the seat and seat back together first to create one component. This will make it easier to create flush edges as you continue the assembly.
     
  10. Fasten seat component to sides. The standard for chair seat height is 18” to the top of the seat. But choose a height that will work best for you.
  11. Finish fastening the sides and add the shoe shelf. The shoe shelf angle is up to your liking. I kept it fairly flat so the edges would flush out with the front and back of this bench.
  12. For reinforcement, you might want to add 2" x 2" posts measured to fit between the bottom of the seat and the top of the shoe shelf. From the outside of each corner, add 3-4 screws per piece. 
  13. The doors I used were paint ready so they can take stain, varnish or paint.
  14. Use your imagination! I used a door for the seat back but a piece of black iron handrail, some slats or even no back at all will work, as well. 

Be creative and have fun! - Remember the ReStores are great places to find these and a myriad of other awesome re-use materials for your projects!! - Good luck and be safe with those tools :)

 

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