Project: Rustic Bench

[Jim Becker]

The barn where we keep our horses recently completed the new bathroom/changing room. It's a very nice conditioned space that will add to everyone's comfort...but it was missing a seating accommodation for folks when they are changing clothes and footwear. This little project fixed that.

I had some very old (and dry and rock hard...) 6/4 white pine lying about that was perfect for this bench. It would end up matching the rest of the barn's coloration (built only two years ago by some amazing Amish builders) and provide opportunity to do a little hand-tool woodworking for some aspects of construction. The bench is 3' long and 18" tall. It features an asymmetric design that allows it to fit into the available space well. In addition to some hand-cut dovetails on one end, it was also necessary to put in a butterfly to reinforce the other end due to defects in the board. Some other reinforcement was done on the bottom of the board, but using, um...metallic materials since they would pretty much be out of sight. This is almost a "one board" project with the exception that the stretcher is from a thicker piece of material that originally served as a railing post from an old barn. Finish is BLO, three sprayed coats of de-waxed shellac and three sprayed coats of Polycrylic. (Yea, I know...but it's easy to come by. :) )

Here's a build sequence leading up to the final result:

Cutting the dovetails was a pain in the you-know-what with this wood...rock hard stuff. Tails were done first.

http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6241_zpsppbhxw9e.jpg

And then the pins
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6240_zpsvylksedp.jpg

Test fit...this works. Not "fine furniture" quality, but great for the purpose at hand. Gaps were later filled with wood slivers, etc.
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6253_zpseu1cxcai.jpg

Example of some of the reinforcement of a lengthwise crack on the under-side
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6256_zpsiqn5pldr.jpg

Rebate for the leg on the non-dovetailed end cut on the slider for convenience and then cleaned up with a hand-plane
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6257_zpsfp0qa0nv.jpg

Walnut bowtie on the top at the non-dovetailed end to insure the lengthwise crack was stable
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6255_zpsg8a00yjh.jpg

Test fit so measuring for the stretcher could be done
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6258_zpsn8naqksc.jpg

http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6259_zpsd59ngaly.jpg

On the front side, I installed some feet to provide an anti-tipping effect
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6260_zpsshjwxypz.jpg

Clamped up with the stretcher installed. The stretcher has through-tenons into the legs for strength
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6261_zpstc9bnrl4.jpg

http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6262_zpsucug5xdu.jpg

Glue-up complete and time for "cleaning up" the joinery and sanding
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6274_zpsbjlfwtah.jpg

While most of any gaps were filled with wood slivers, I did eventually use just a little putty in places that I was having difficulty getting wood into. Later, after the first coat of shellac, I used an 00 brush and some color mixed acrylic paint to blend in anything that stood out as best as possible. Because of the environment where this bench would go, I preferred to do this rather than leave gaps to collect dust and "other things" that frequent a horse barn...
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6347_zpswn4na2pl.jpg

Oiled and coats of shellac sprayed
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6348_zpsow2im5jy.jpg

[Jim Becker]

With the acrylic sprayed and ready for delivery
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6360_zpsmrifvnmp.jpg

http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6361_zpslylubfx5.jpg

http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6363_zps2hrxmgvg.jpg

"Installed" in the new bathroom/changing room at the barn
http://img.photobucket.com/albums/v646/a-j-adopt/Woodworking/IMG_6369_zpsl13t3onf.jpg

[Jebediah Eckert]

Wow, really nice, but where do you put the horse tack ?

[Jim Becker]

Wow, really nice, but where do you put the horse tack ?

LOL...on the horse, of course... :D

[Lee Schierer]

Nice bench Jim.

I've always wondered how well that shoulder plane works I have one on my wish list.

[Jay Jolliffe]

Bench looks great. Thanks for doing the build pictures...Looks like that will last a real long time.

[Jim Tobias]

Nicely done!! Fits the use and should hold up forever.

JIm

[Scott DelPorte]

It looks perfect for the job and strong enough to hold up to barn (ab)use. I might copy that for our tack room.

[Mike Wilkins]

Nicely done Jim. I love the look of old pine lumber, as I have a stash of some old heart pine awaiting the right project. The finish routine really makes the grain pop. Thanks for the finish schedule as I plan to utilize the same.

[Ken Fitzgerald]

Nicely done Jim as always!

[Jim Becker]

It looks perfect for the job and strong enough to hold up to barn (ab)use. I might copy that for our tack room.

This general type of "Hefty" build is a good design for that purpose. The sitting bench in the tack locker room at our barn is of that nature, although doesn't have the "character" of really old lumber nor the joinery. :)




I've always wondered how well that shoulder plane works I have one on my wish list.

It works pretty good for this, although I probably should have spent a little time doing some sharpening first. "D'oh!!"

[Frank Martin]

Jim, this looks great! For the finish did you use Target Coatings or something else?

[Barry Dima]

Great project with great wood. That asym design works really well; it walks my eye right to the bow tie and keeps it there.

Also, your shop looks full of fun.

[Prashun Patel]

That's a lovely bench. I really like the foot treatment and the asymmetry too.

[Mike Ontko]

Nicely done! It's amazing what can be done with a few pieces of scrap :) And all formal too, with dressed shoes, tails, and a bow tie.

[Jim Becker]

Jim, this looks great! For the finish did you use Target Coatings or something else?
Finishing regiment is described in the first post... not Target Coatings this time around--for expediency.

[Jim Becker]

That's a lovely bench. I really like the foot treatment and the asymmetry too.

Thanks. Sometimes "different" is refreshing...


And all formal too, with dressed shoes, tails, and a bow tie.

ROFLOL!!! Indeed!

[Andrew Hughes]

I also like the bench,also glad you didn't stain it. The natural color looks great.With your own design.Thanks for sharing.

[Jerry Olexa]

Very nice work, Jim.....Love that bowtie and the DTs...

[Gordon Eyre]

Excellent work Jim and most appropriate for the environment where it is used.

[Gary Ramsey]

Really nice. Love the design.

[Ted Calver]

I really like the way this turned out, Jim. Fits like it belongs. Great job!

[Jim Becker]

Folks at the barn seem to like it...which, of course, makes me happy. :)