X Bench

Tyson
by Tyson
2 Materials
This was a simple stool, built for my sister. I used oak, and joined the cross members with a full lap joint, pinned with a through tenon.
Well, I think those are the correct joint names anyway. The lap joints were cut with a table saw sled, using the standard blade and multiple passes. I cut the opening until it was almost done, then nibbled away the rest testing the fit until it was perfect.
The through mortises were cut with a mortising machine, and this was close, though the final tenon fit was a bit loose so I glued a thin slice into the gap for a seamless joint. The tenon was cut using the "speed tenon" technique from Fine Woodworking.
The covering was made from a couple of bed sheets bought at a thrift store, an inside cover from a flannel sheet to help shape the cushion and an outer cover from a simple grey sheet. I admit I wasn't overly bold with fabric choices. I simply sewed the corners to match the height of the cushion, pulled them tight and fastened them with numerous staples to the plywood top that was screwed to the x-base.
It was a fun build, made a few mistakes, which is pretty standard for my builds, but in the end my sister loved it and that's a success for me!
Cutting the lap joint in multiple passes.
Test and take off as little as possible to sneak up on the final fit.
The mortises are cut.
Test assembly and mark and cut the 45 degree angle at the top and bottom to make the legs and top flat.
The top frame is built.
A plywood rectangle is cut at the same size as the top frame that will be used to attach the cushion. I routed all the edges and also drilled some holes to release air when sitting on the cushion.
The bench was glued and the through tenon was cut and chamfered.
The oak was finished with a dye, tung oil and shellac.
A foam cushion was cut to size and measured for height.


Based on the height of the cushion and plywood, the fabric was cut to size and the corners sewn closed.
Based on the height of the cushion and plywood, the fabric was cut to size and the corners sewn closed.
The first layer is placed over the cushion, pulled tight and stapled in place.
After the first layer was attached, it was trimmed close to the staples, and the 2nd, outer layer was attached and trimmed in the same way.
The cushion top is screwed into place and the X bench is complete.
Now it's taken inside and used as a foot stool for putting on fancy boots!
For the full process, follow along with this video.
Suggested materials:
  • Oak
  • Fabric   (Thrift store)
Frequently asked questions
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  1 question
  • Gladys Benitez Gladys Benitez on Jan 27, 2017
    Hello, X Bench Builder....Your a considerate husband, indeed. Your BD gift to your wife is just beautiful. Can you explain the 'purpose' for the 'plaid' covering-2 layer process??? I must of missed something somewhere....I didn't view your entire video:(:(. Thank You. G from Texas.
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