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Most plywood only has five plies (plies are individual l/n” to 1.h6″ planks of wood that are layered together in cross-grained stacks), but Baltic birch has seven or more. The other thing about Baltic birch is that, while most plywood has knotholes or voids in some of the plies, Baltic birch plywood is fabricated with all the knotholes or voids filled or plugged. This last bit of sage plywood arcana is what led me to my little design epiphany. Have I confused you yet? Stay with me, people. Anyway, instead of laying the plywood flat as you’d expect, I decided to stack the pieces in such a way that the edges would be exposed on the top and sides of the bench.
It involved a little math to get the dimensions right, but I’ve got it all figured out and I’m passing on the instructions to you. 210 Appendix Wood you’ll need: Bench Top 12 pieces of Baltic birch plywood, which you’ll cut to 22″ long by 2″ wide each 11 pieces of Baltic birch plywood, which you’ll cut to 18″ long by 2″ wide each (you want to actually make these a hair shorter than 18″ long, which I’ll explain in a minute) Bench Legs 24 pieces of Baltic birch plywood, which you’ll cut to 16″ long by 2″ wide each (again, on these, make them a hair shorter than 16″ long) 22 pieces of Baltic birch plywood, which you’ll cut to 18″ long by 2″ wide each Pretty simple so far. The reason those pieces need to be a hair shorter, is so that when you do the final assembly the slats extend a little “proud” on your lap joints. At the end, you can sand it all flush.
Tools & other stuff you’ll need: Table saw Carpenter’s wood glue Assembly hammer (rubber mallet) Sandpaper Polyurethane (optional) Clamps Brad nailer (optional) Now for the fun part: 1. Cut your wood to size with a table saw and make sure all your edges are clean of any “fuzz” from cutting. Then start stacking. We’ll make the bench in 3 pieces, and then assemble the 3 pieces last for the final product. For the top: 22. Work on a flat surface and keep a good straightedge handy. Start with one of your long pieces. Apply a light coat of glue across its surface. Apply glue to a shorter piece’s surface, then carefully stack them so that the• long and short pieces create “fingers” of equal length on each side. Continue alternating lengths on top of one another.