Outdoor Crate Bench

by JOANN |

Item # 052478745P219

Intermediate Weekend Project

Use sandpaper to soften all sharp edges of crate slats.
In a designated spray area, spray one thin coat of clear varnish to act as sealant over all surfaces of crates. Let dry. Lightly sand all over. Apply a second coat to all surfaces. Let dry. This will ensure that the wood will not absorb any stains and make the crates easy to clean.
Attach the crates together in sets of three.
Set each crate on end, handle end up, open sides facing the same direction. Place sides of 2 crates together so that the sides are flush.
Mark points 1" from sides, on the slat closest to the open end of crate and the slat furthest from the opening for the bolts (4 marks on each crate).
Drill holes at these points. Screw bolts through the holes. Attach a locking nut on the end of each bolt and tighten. Repeat to make 2 sets of 3 crates.

Prepare the Foam cushion.
Set 2 sets of 3 crates opening sides together. Measure the top surface area width and length. Approximately 18 1/2"x 37".
Use a ruler and permanent marker to mark the width and length onto one large surface of the cushion foam. Use an electric knife, serrated bread knife or bandsaw to cut the foam.
Center the foam on the cushion wrap.
Spray adhesive on the flat surface of the foam closest to the wrap. Immediately lay the foam down, centered on the wrap. Flip and hand press the wrap flat on the foam. This will be the top of the cushion. Flip the foam and wrap. Spray adhesive on one side of the foam at a time and immediately press the wrap to the foam. Trim away excess wrap at the corners and edges. Angle cut the wrap to fold to the bottom of the foam without overlapping the wrap.

Match the two pieces right sides together. Sew a basting stitch along the long edge.
Press seam open.
On wrong side, center zipper right side down over the seam. Pin in place.
Sew down both sides of the zipper tape, close to zipper teeth using a zipper foot.
Remove basting stitches. Zipper should connect the two pieces and move freely along the seam.
If needed, secure ends and trim zipper to fit the length of the panel.
Side back piece should now be the height of the side front piece, trim if needed to match.

Hem one long edge of each piece by pressing edge in 1/2" and then again 3/4". Stitch.
Sew hook side of Velcro tape to the right side of one hemmed edge. Align tape about 1/4" from edge.
Sew loop side of Velcro tape to the wrong side of the other piece's hemmed edge. Align tape about 1/4"from edge.
Overlap pieces, matching Velcro strips together. Side back piece should now measure the same height as the side front piece.

Sew the side pieces to either end of the side front piece at short ends. Use 1/2" seam allowance and leave 1/2" open at the top and bottom of each seam. This will allow the sides to turn around the corners of the top and bottom panels.
Sew the side back piece to the side pieces at their other end, forming a loop. Use 1/2" seam allowance and leave 1/2" open at the top and bottom of each seam.
Pin side loop to the bottom cushion, matching sides and corners. Sew using 1/2" seam allowance, pivoting at corners.
If using a zipper closure, make sure zipper is open before the next step.
Sew opposite end of the sides to the top cushion using the same steps at the bottom cushion.
Turn cushion cover right sides out through the Velcro or zipper opening.
Insert prepared cushion or cushion foam into the cover.