Albert Blog: DIY Wood Chevron Bench with Box Frame

Hi, it’s Amy from Hertoolbelt back with another build plan, this time for a wood chevron bench, with a pieced stained wood top. It will look great at your dining table, at the end of your bed, in your entryway, or anywhere else you need a bit of extra seating.

I love the look of the rustic chevron top. I used pine for the top chevron, which can easily be switched for any wood type that you like (reclaimed lumber would look awesome). You can easily customize the look of this bench with various stain colors and paint colors.

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This chevron bench is inspired by a super cute bench from West Elm, so if you’d rather buy than build, you can buy it here. Their version has metal legs/frame, my version sports all wood legs to make the building process simple and less expensive. The legs for this bench were changed a little to make a sturdier rectangle end with a more modern box frame style.

How to Build a DIY Chevron Bench

Click Here to Get a Free Printable Version of This Building Plan

Materials

3 – 2″ x 2″ x 8′ boards (actual dimensions 1 1/2″ x 1 1/2″)
3 – 1″ x 3″ x 8′ boards or 1″ x 4″ x 8′ boards
2 – 1″ x 2″ x 8′ boards (I usually rip a 1×4 in half to make these to make sure the edges are straight.)
1 – 2′ x 4′ piece of 3/4″ plywood (or a cheaper method is 2 pieces of 1″ x 4″ x 8′ boards)
2 1/2″ pocket holes screws
1 1/4″ brad nails
wood glue
wood filler
sandpaper
primer/paint
stain
top coat
- Approximate lumber cost for pine: $36

Cut List

Base
2 – 1 1/2″ x 1 1/2″ x 45″ (2×2)
4 – 1 1/2″ x 1 1/2″ x 16 1/2″ (2×2)
6 – 1 1/2″ x 1 1/2″ x 12″ (2×2)
Bench Top
1 – 3/4″ x 13 1/2″ x 46 1/2″ plywood (or alt 3 – 3/4″ x 3 1/2″ x 46 1/2″)
2 – 3/4″ x 1 1/2″ x approximately 48″ long with 45 deg miters on each end – cut to fit (1×2)
2 – 3/4″ x 1 1/2″ x approximately 15″ long with 45 deg miters on each end – cut to fit (1×2)
as needed 3/4″ x 2 1/2″-3 1/2″ x 9 1/2″ with 45 deg miters on each end (1×4 or 1×3)
as needed 3/4″ x chevron piece ends (1×4 or 1×3)

Step 1: Cut and assemble leg bases

Cut all of the (2×2) pieces for the base. Drill pocket holes for 1 1/2″ material in both ends of all of the 12″ and 45″ pieces.

Attach 12″ (2×2) pieces flush with the top and bottom of a 16 1/2″ leg with wood glue and 2 1/2″ pocket hole screws. Attach another 16 1/2″ leg to the other side of the 12″ pieces to create a rectangle. Repeat for other rectangle leg base.

Step 2: Assemble box frame

Attach a 45″ (2×2) piece flush with the top of a 16 1/2″ leg, with wood glue and 2 1/2″ pocket hole screws. Attach the other end of the 45″ piece flush with the top of the other rectangle leg. Repeat for the other 45″ piece.

Measure and mark over 14″ from the ends of the 45″ pieces. Use wood glue and 2 1/2″ screws to attach 12″ supports between the 45″ pieces.

Base assembled

Step 3: Build the chevron bench top

The chevron bench top is made with slats that are attached to a plywood piece, and the plywood is the most expensive part of this project. You can substitute 3 – 1×4’s for the plywood for a less expensive option, however it is possible the 1×4’s aren’t straight and flat, your choice.

The width of the chevron slats does not really matter (I used 3″ wide trimmed down from 3 1/2″ boards). When making the chevron slats, the bulk of the slats will be 9 1/2″ long with 45 deg miter cuts on each end. Then the end pieces will be cut to fit.

For the plywood option: cut the 3/4″ plywood piece to 13 1/2″ wide x 46 1/2″ long.

For the 1×4 option: cut 3 pieces of 1×4 that are 46 1/2″.

Start the chevron pattern with two pieces cut making a point at one end of the center of the plywood. Use wood glue and 1 1/4″ brad nails to attach to the plywood.
Continue cutting 9 1/2″ chevron pieces to fill the bulk of the top, use wood glue and 1 1/4″ brad nails to attach to the plywood.
Cut end pieces to fit and fill in top. Tip for cutting the pieces, measure the length of the adjacent pieces to get the length of the new piece that needs to be cut. For example on the top pieces, the long side is 9 1/2″, the short side will be the same as the long side on the small corner piece. Attach these pieces with wood glue and 1 1/4″ brad nails. Trim the entire top piece as needed.

Step 4: Measure and attach edge banding

Cut the edge bands from 1×2 pieces, you’ll cut 45 deg miters on each end. Measure the length of the chevron top, this will be the inside dimension of the long edge band. Measure the width of the chevron top, this will be the inside dimension of the short edge band pieces. Attach the edge bands with wood glue and 1 1/4″ brad nails.

Unfinished base and chevron top

Step 5: Fill, paint, and stain

Let all of the glue dry. Use wood filler as needed to fill in cracks and blemishes as needed and allow that to dry. Sand the bench top and base pieces smooth. Paint and stain the bench top and base as you like. I primed the base with paint primer then painted it with white latex paint. I stained the chevron top with Minwax golden oak and followed that with Minwax aged oak to add a little definition in the cracks and define the chevron pattern. The aged oak made the top slightly darker that I hoped. I let the stain dry overnight and lightly sanded the dark from the surface of the pine and reapplied a light coat of golden oak. I let the stain dry and applied a coat of Minwax semi-gloss polyurethane to protect the surface.

Step 6: Attach the bench top to the base

To attach the chevron bench top to the base, use a countersink drill bit and drill pilot holes in the base. Use 2 1/2″ screws to attach the base to the top.