By Chris HillMore in Outdoors
Wings -- four pieces at 3/4" x 7-1/4" x 11"
Long Filler Strips -- two pieces at 3/4" x 1-1/2" x 11"
Short Filler Strips -- two pieces at 3/4" x 1-1/2" x 11"
Stiles -- two pieces at 1-1/2" x 2-1/2" x 43-1/2"
Feet -- four pieces at 1-1/2" x 2-3/4" x 18-1/2"
Bottom Rungs -- two pieces at 3/4" x 1-1/2" x 31"
Middle Rungs -- two pieces at 3/4" x 1-1/2" x 31"
Top Rungs -- two pieces at 3/4" x 1-1/2" x 31"
Cut the four wing pieces (two for each side) to length using a hand saw or miter saw.
Mark a 1-inch grid pattern on one of the wings blank using the template. Use the arc pattern to transfer the arc pattern on the blank (images 1 and 2, below).
Use a jigsaw to cut the pattern. Trace the shape of the arc on the remaining wing piece and cut them to shape (images 3 and 4).
Position two wings with the long and bottom edges flush, clamp in place, and sand to a uniform shape (image 5). Repeat for the other two wings. Keep the wings in these pairs for assembly later.
Cut the long filler strips to length to match the height of the wings (image 1). Cut the short filler strips to match the distance between the bottom outer edge of the wings and the long filler strips.
Apply the finish of your choice to the wings, long filler strips, and short filler strips. We used Cabot Solid Color Acrylic Siding Stain (Evergreen) which acts as a primer/sealer and top coat in one.
After the finish has dried, position the wings and filler strips and attach using glue and #18 x 1-inch galvanized or stainless-steel wire brads.
Rip a 2x4 on a table saw to create the stock for the stiles and feet. Cut them to length with a hand saw or a miter saw.
Use the pattern to mark the radii on the stiles and feet and use a jigsaw to cut the parts to shape (images 1 and 2).
Position the stiles with the straight end and edges flush, clamp in place and sand the rounded ends to a uniform shape.
Position the feet with the ends and edges flush, clamp in place, and sand the rounded corners to shape (image 3).
Use the pattern to mark the placements for pocket holes on the end of the stiles. Set the pocket-hole jig and drill bit for drilling into 1-1/2" stock and drill the holes in the stiles (images 4 and 5).
Apply a finish to the stiles and feet and allow to dry. We used Cabot Solid Acrylic Siding Stain (Redwood) on the feet and Cabot Australian Timber Oil (Jarrah Brown) on the stiles. Be sure to not apply the oil on the end of the stiles that join to the feet and 9 inches above the end on the face with the pocket holes.
Attach the stiles to the feet using glue and 2 1/2" pocket-hole screws (image 6).