As stated before, I build the bench bottoms out of either 1/4" Luan Mahogany plywood or 3/8" Birch plywood depending on the quality and strength the client wants. The bottom is either attached to a rabbet along the bottom or recessed in a dado groove 3/8" from the bottom of the rails. To make the bottom that fits in the dado, assemble your bench carcass and legs as a complete unit. Measure the distance between the inside of the dado on opposite sides. Whatever the measurement is subtract 1/16" and cut it out. For the corners measure in from the legs to see what size cutout must be made for the legs and make the cutout 1/8" greater than measured. Make these cutouts square as it is very visible to the client if they are cut at anything other than right angles. When cut out, take the bench apart and make sure the bottom fits without pushing out on the rails. Remember it is supposed to float in place. If this is the type of bottom you are making you are through with this part. If your bottom is going to fit in the rabbet in the bottom measure the distance between where it is going to fit in both directions and subtract 1/16" from both dimensions. Then make the cutouts as directed above. Dry fit the bottom. It should fit without pushing anything out of square. James Grebe R.P.T. from St. Louis pianoman@inlink.com "Only my best is good enough"
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