1

Draw an arc on each side stretcher by hooking a tape measure on a screw driven into the work surface. Draw the arcs on the legs using a compass or coffee can, then cut out all the arcs with your jigsaw.

2

Clamp together the legs and outside stretchers to make a frame. Lay the sheet metal on it, then position the inside stretchers. Use a spacer to get the stretchers centered, then screw them on to lock everything together.

3

Screw filler pieces between the stretchers, then add cleats to hold the bottom. Be sure to predrill and countersink all screws.

4

Nail the front, back and sides together. Predrill for each nail, and drive the nail heads slightly below the surface with a nail set. For additional strength, run a bead of glue along each joint before assembling.

5

Clamp the arm support to the filler piece, screw them together, then add the lid support.

6

Mark the notches for the arm supports directly from the bench. Cut out the notches with a jigsaw, then round off the protruding corners.

7

Place the arm assembly in position and nail it to the legs and stretcher. There will be a pocket formed at the top where the arm cleat will go (see next photo).

8

Attach a cleat to the underside of each arm, using diagonal lines to center it. Place the arms on the bench and nail through the cleats to secure them.

9

Fasten the hinges to the bench. Rest the bench on its back, on top of 1-inch blocks, center the lid in the opening, then screw it on. Give the whole bench a once-over with sandpaper, and you’re ready to finish!