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Attach all four legs and set the top on the base with equal overhang on all sides. Carefully trace the leg tops on the bottom side of the planks and then flip it over onto a work surface. Drill a 1/2” hole with each square mark near the line but not touching it. Using a jigsaw, carefully cut out each square. Because leg tops will nest snuggly in these squares, be sure cuts are slightly undersized. Flip the top back over and attempt to set it on the base. Using a flat wood file and chisel, remove small amounts of material as needed. Once the top nestles down on the gutter structure without excess force, run a small bead of wood glue on the top edges of the gutter, reposition the top and shoot 15-gauge finish nails through the inside edge of the gutter into the bottom of the tabletop. Fill in small gaps between the leg top and table planks with wood filler or small wood shims.
With the stain dry, I began to build the tabletop. Others might have chosen to build first and stain second. But I felt that, given the combination of colors being used, I was most likely to achieve satisfying results—or less likely to mess up—if I stained the boards before I joined them together. The picture above shows the unfinished undersides of the boards after I had almost finished fastening each one to its neighbors. First, I marked off where the pocket holes would be located. For each regular board, I planned to put in at least two pocket holes. I needed to put additional holes in the boards at the two long edges, because those boards would need to be secured not only to those in the adjoining row, but also to each other. Finally, after creating the pocket holes, I assembled the tabletop one row at a time, driving in the screws that magically brought the disparate pieces together into a cohesive surface.
Luckily, we have also managed to find a detailed video tutorial of the Barn door project that illustrates the process of building a Barn door of your own. The steps and instructions in the video tutorial are different from the source links listed above. Actually, you can make different types of designs for your Barn door depending on which one you can afford easily and DIY on your own.
While the top is drying, measure the thickest portion. Add 1/16” to this measurement and mark a horizontal line with a framing square across the tops of the table legs. This line marks the gutter structure mounting depth. Legs will protrude 1/16” above the plane of the tabletop. Ask a helper to hold the leg tight to the inside corner of the gutter structure with the mark at the top of the gutter. Drive at least two wood screws through the inside face of the gutter into the sides of the leg.
Drill pocket holes from the outer boards to the inner board. Drilling the holes before adding screws prevents the boards from cracking. To create the holes, measure along the sides of the center board. Mark it about every 7 in (18 cm). You will need to use a very long drill bit, about 3 in (7.6 cm) wide, called a pocket hole drill bit. Drill at an angle down through the side boards and into the side of the center board every 7 in (18 cm).
A quality wood moisture meter is vital to the long-term success of any woodworking project you put together. Lumber mills try to dry their batches of lumber according to the intended end product destination. That is, if the wood is harvested in the wet Northeast, but is going to be shipped to the arid Southwest, it will be dried more than wood kept in the Northeast for use by woodworkers. The success of your woodworking project, from wood flooring to kitchen cabinets to fine furniture, depends on the correct moisture content levels of the woods you use for your area of the country.
Reclaimed Wood from Corn Crib HOW TO DESIGN AND BUILD AN ENTRY WAY COAT RACK AND BENCH There was a door in granddad’s home the client wanted to preserve and wondered, if they provided the wood, could I build an entryway coat rack and bench using the door as part of the build. The wood they wanted to provide, well, that was from the family owned Tennessee corn crib that had been torn down and they didn’t want to lose the wood or the memories. Not only was this a corncrib but it was eventually used by the great grandchildren as a play house. So for the client there are as many memories in this build as there are colors. THIS PROJECT TRULY DEFINES THE “CUSTOM” in BAYNE CUSTOM WOODWORKING. I spent some time to design a simple layout in @sketchup_official so the client could approve the idea I had in mind. The wood showed up in two deliveries so we stacked it outside because this was the first time I worked with barn wood. I did not want to introduce possible termites to my shop. So my first call was to my pest guy asking how I would treat the wood for termites. Much to my relief he said I had nothing to worry about. This was “real” wood! Not nominal at all, nominal is how we buy our wood at a local hardware store. Where a 2×4 is actually 1 ½ x 3 ½ . These 2×4’s were at least 2”x4”’s if not more and were hard, heavy and dusty, did I say heavy? After cutting to length on my handy @DewaltTough miter saw, I had to take them to my @ridgidpowertools table saw and square up the bottoms only. I was very careful not to lose any of the original saw marks and character because that would ruin the entire purpose. For someone who likes clean, crisp edges, this was a bit of a challenge. I used @kregjig Kreg Jig® K4 Master System to join all the pieces of the base, the seat frame and the supports to join the two together. I was very careful to hide all of the pocket holes so they could not be seen from any angle. I used Titebond Products original interior wood glue to join all the pieces together. The next item was to assemble the back which included grandad’s door as the center piece. The door was only 71 ½ tall which determined the overall height of the project. Part of this back also includes two live edge pieces that we picked to use as the “L” shaped wings or side walls. The door measured 24” which left me with 6” on each side to make up the final size of 36”. So I chose two of the straightest boards that were closest to 6” and cut them to width so as not to waste any wood or lose any character. I used the Kreg Jig® K4 Master System
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