---
title: Create a bench with 2x4 beams
slug: create-a-bench-with-2x4-beams
description: This tutorial explains how to build a bench using 2x4 extruded beams. The finished bench will weigh over 80 pounds (approximately 36 kilograms).
tags: ["untagged","extrusion","PP"]
category: Products
difficulty: Medium
time: < 1 week
location: Baltimore, United States of America (the)
---
import { Image } from 'astro:assets'
# Create a bench with 2x4 beams
<Image src={import('./0F336C0F-D886-450F-ACB0-018852CC6746.jpeg')} alt="Create a bench with 2x4 beams" />
This tutorial explains how to build a bench using 2x4 extruded beams. The finished bench will weigh over 80 pounds (approximately 36 kilograms).

User Location: Baltimore, United States of America (the)
## Steps
### Step 1: Prepare your material and equipment

This process requires the following tools and equipment:

- V4 Extruder
- 2x4 mold (1.5 in x 3.5 in x 6 ft)
- Approximately 85 lbs (38.6 kg) of shredded PP plastic
- Cooling tank
- Miter saw
- Drill
- Drill bits
- Deck screws

Once you have gathered all your materials and equipment, you are ready to begin.


<Image src={import('./IMG_2914.jpg')} alt="IMG_2914.jpg" />


<Image src={import('./0B5036DC-73BC-43D1-A866-388DC1EF0E54.jpeg')} alt="0B5036DC-73BC-43D1-A866-388DC1EF0E54.jpeg" />

### Step 2: Prep

Ensure all plastic is thoroughly cleaned, sorted by type (and color if necessary), and shredded to the desired flake size. For our bench, we used PP (#5) plastic.


<Image src={import('./8E4E2360-A83C-4F60-B586-FC2A0CD4E900.jpeg')} alt="8E4E2360-A83C-4F60-B586-FC2A0CD4E900.jpeg" />

### Step 3: Extrude

With the plastic prepared, it is ready for extrusion into beams. Set the extruder temperature to 240°C (464°F) for PP plastic. Attach the mold. Begin extruding at 45-50 RPM, ensuring the hopper remains filled. Once the 6-foot (1.83-meter) mold is filled, disconnect it and place it in a cooling tank with cold water for approximately 20 minutes. After the plastic solidifies, remove it from the mold. Repeat until you have eight 6-foot beams.


<Image src={import('./41A2A2FB-D5D0-4338-8D7C-9D86910A5AFD.png')} alt="41A2A2FB-D5D0-4338-8D7C-9D86910A5AFD.png" />


<Image src={import('./3E4055E8-9696-4D7F-84C0-282E2F72F0CF.jpeg')} alt="3E4055E8-9696-4D7F-84C0-282E2F72F0CF.jpeg" />


<Image src={import('./75723621-75E5-4EE8-9A56-33FFAB013207.jpeg')} alt="75723621-75E5-4EE8-9A56-33FFAB013207.jpeg" />

### Step 4: Cut

The beams should first be trimmed to remove any excess material at the ends. Next, cut the beams to the specified dimensions using a chop saw:

- (4) beams, each 5 feet 4 inches (163 cm) for the Benchtop
- (1) beam, 60 inches (152 cm) for Ground Support
- (4) beams, each 16 inches (41 cm) for the Legs
- (6) beams, each 15 inches (38 cm) for the Braces
- (2) beams, each 11 1/4 inches (29 cm)


<Image src={import('./9EB14FD3-C6DB-446D-B4A3-96862F864829.png')} alt="9EB14FD3-C6DB-446D-B4A3-96862F864829.png" />

### Step 5: Staging 

### Assembly Instructions

Lay out the four longest beams side by side to form the bench top, maintaining a spacing of approximately 0.25 inches (6.35 mm) between each. Attach the braces at the ends of the bench top.


<Image src={import('./C6BE9A60-C56D-4F45-844D-35403C94FE3F.jpeg')} alt="C6BE9A60-C56D-4F45-844D-35403C94FE3F.jpeg" />

### Step 6: Assemble

At this stage, attach the beams using 2.5-inch (6.35 cm) deck screws. Pre-drill pilot holes to prevent cracking.


<Image src={import('./690FCC2F-B093-41A3-BA71-DE0A7291EA13.jpeg')} alt="690FCC2F-B093-41A3-BA71-DE0A7291EA13.jpeg" />

### Step 7: Attaching legs

Begin assembling the bench on a tarp to collect drill shavings for potential reuse. Position the 16-inch (40.64 cm) beams at each corner as legs. Drill pilot holes and secure with screws.


<Image src={import('./20177182-8578-4860-B090-5C4EE57F8C14.jpeg')} alt="20177182-8578-4860-B090-5C4EE57F8C14.jpeg" />

### Step 8: Attaching supports and braces

With the bench top and legs prepared, the next step is to reinforce the structure. Position the 15-inch (38 cm) beams between the legs as braces. Next, use the 11 1/4 inch (28.5 cm) beams to install a perpendicular support, connecting the bench top to the 60-inch (152 cm) beam that spans the base.


<Image src={import('./1D8056DD-DCEC-4F02-B349-B629583EB24D.jpeg')} alt="1D8056DD-DCEC-4F02-B349-B629583EB24D.jpeg" />


<Image src={import('./6F3DF443-481D-438A-B68E-BCA7C550AB41.jpeg')} alt="6F3DF443-481D-438A-B68E-BCA7C550AB41.jpeg" />

### Step 9: Enjoy!

Choose a suitable location to install your bench, such as a backyard or park.


<Image src={import('./4C777FB3-02A1-4140-9D1E-3A972B663873.jpeg')} alt="4C777FB3-02A1-4140-9D1E-3A972B663873.jpeg" />


<Image src={import('./F18ED2D8-B35D-40B4-941E-A843A0870B2C.jpeg')} alt="F18ED2D8-B35D-40B4-941E-A843A0870B2C.jpeg" />


<Image src={import('./21F32179-FAE1-4CAA-806C-B5C53C15ABC6.jpeg')} alt="21F32179-FAE1-4CAA-806C-B5C53C15ABC6.jpeg" />