I originally designed this bench as a chair with only one cushion. It was meant to be that way all the way until I did a test assembly of the components (before cutting down the length of the seat and backrest. I ended up preferring the proportions of the three seater bench and left those pieces long.
One of the most laborious steps, which the video doesn't quite capture, was sanding off paint with a random orbital sander. The 2x6 components that form the legs were reclaimed wood from part of the house. The while clip of sanding lasts only a few seconds, I was sanding paint for nearly 3 straight hours.
Also, this was my first time using steel components in a project. I didn't have much experience or equipment, but the design needed some high strength low profile pieces. The grinder was a very intimidating tool, so I worked slowly and carefully. The hole drilling was simple enough, but took a really long time (relative to what I've come to expect from wood).
The cushions were a particular nightmare to source. Most of the chair cushions online are just a small pad that you'd put on a dining chair. The best I could find were a set from Ikea. Since it was originally going to be a single chair, I only the first cushion set to test out the proportions before finalizing the design. By the time I'd decided on a full bench, however, Ikea was sold out of the cushions. According to the rep, they were supposed to come back in stock soon, so I waited a week or two, and still no cushions. That's when I started getting desperate and calling other stores. I almost drove 6 hours to pick some up in LA. I started calling the Ikea's in Chicago and Houston to see if one of my siblings could get their hands on these darn cushions. Eventually, my mom saved the day by snagging 2 more sets at the Dallas Ikea. YAY!
The bench looks great, Nik, and I must say the cushions are pretty fabulous. Uncle Craig and I decided (I decided) that we would spend last weekend’s quarantine redoing the bathroom cabinets. Our first foray into using an orbital sander! Pretty cool, though I agree, after a few hours it was laborious. On to the next project!