Furnishing a Sauna Suite #11: Assembling Bench Frames

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Blog entry by DustyMark posted 02-12-2021 08:22 PM 399 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 10: Suction-Fit Tenons Part 11 of Furnishing a Sauna Suite series Part 12: Screw Cleats and an Extra Set of Legs »

Glue Legs

I applied a liberal amount of polyurethane construction adhesive to the mortise and the tenon.

I used a total of six clamps to hold the frame as the glue cured.

Peg Tenons

After removing the clamps, I used 5/16” dowels to peg the tenons. These provide a mechanical safety in case the glue joint fails. A flush cut saw cleans up the extra dowel nicely.

Build Braces

These benches must hold the weight of two adults. Pocket screws weren’t a good option to fasten the braces since they depend on the strength of the screws and don’t gain much strength from end grain glued to long grain.

A small cleat is screwed and glued to the brace. This is long grain joined at 90 degrees. It’s only a 3 3/4” span, so I’m not concerned about cross grain joint failure.

The entire brace assembly is glued and screwed to the inside of the rail. This is also long grain glued at 90 degrees, but the glue joint is incredibly strong.

I labelled and dry clamped all the braces and used the tip of a 3/16” drill bit to mark the exact location for pilot holes.

A scrap of dowel kept me from drilling though the rail.


Fasten top slats.

-- Mark, Minnesota

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