Step 1 To cut laminated panels in half lengthways, mark centre at ends, then position and clamp straightedge to panels to guide the circular saw, with the blade on the centre mark.
Step 2 Use a protractor to set a sliding bevel to a 5° angle. After unplugging saw, place stock of bevel on base plate of saw and adjust angle of blade to meet arm of bevel.
Step 3 Make all angled cross cuts using straightedge to guide you. The angles at each end of chair backs go in same direction. Tabletop has angled cuts at each end but in opposite directions. Chair seats and bottoms only have angled cuts at 1 end. Reset saw so it is cutting square and make all other cross cuts in chair fronts, table sides, table bottom and shelf. Table shelf is also less in depth. Measure lengths from long end of angled cuts
Step 4 Drill 5mm clearance holes at square ends of chair seats, bottoms and through 1 end of backs. Holes should be 15mm in from ends and 50mm from each side, with 1 in middle. Also drill clearance holes 286mm up from bottom of chair backs to fix chair seats. When drilling holes through chair backs, angle drill slightly to match angle of cut.
Step 5 Using 120-grit abrasive paper around a sanding block, sand parts to round and smooth all edges. Rounded edges will form a shadow line when joined, emphasising joints, as it is difficult to fully hide them.
Step 6 Bring chair parts together and, using 3mm bit, drill pilot holes through clearance holes into adjacent timber. Remove, glue, then put back together and screw. Drive screws so heads are countersunk into timber. Check seat, bottom and front are square to each other.
Step 7 Once chair back, bottom, seat and front panel are assembled, place slightly long timber for side panel against back so it covers the hole. Reach through front and trace outline of panel on timber. Cut to shape, sand, glue and screw in position. Wipe off excess glue with a rag. On second chair, place side panel at other end of opening so chairs are a mirror image of each other.
Step 8 Screw through table bottom into sides. Place shelf so underside is 240mm from bottom of table and flush with front edges of sides. It will be 30mmm in from back of sides. This makes room for back panel. Screw them all together. Place tabletop on base assembly with angled bevels facing down so it overhangs equally. Screw into sides.
Step 9 To minimise wood filler showing through under gloss finishes, apply undercoat first to seal timber. When dry, fill screw heads. Allow to dry, then sand smooth.
Step 10 Spot-prime, then apply 2 coats of Dulux Super Enamel, Jubilation on chairs and Quince Jelly on table unit. For best results, apply with a roller, then lay off with a brush. Let dry and sand lightly between coats.