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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
If you already have a workshop and the skills for woodworking, you will need to make sure that you have some reliable woodworking plans at your disposal and the necessary woodworking tools to complete the projects you wish to make. There are some websites that offer free woodworking plans, but they are often incomplete or lack sufficient detail to understand properly and this will lead to frustration and loss of interest in woodworking. After spending many years building up your collection of fine woodworking tools and learning to use them, you will no doubt have some neat skills under your belt. Now to make full use of these skills, you will need to find a nice project to work on, one which will do you proud and show off your fancy woodworking skills.
Just redid my dining room table with this technique and I an observation/suggestion others might find helpful. The boards did not line up well putting it together upside down, even on a flat concrete floor with me standing on the boards while they were screwed. I would have combined biscuits with the pocket holes to ensure a better alignment of the boards. Lots of sanding was required after assembly, and this might not be a huge deal with pine, but I used hard maple so it was quite a chore even with a belt sander. Also, be aware that the 1x2s around the edge may not line up perfectly -- I had to trim about an eighth inch from each side after assembly to get nice smooth, even edges. Not a big deal, but the top turned out a little smaller than the specifications I was give by SheWhoMustBeObeyed. Otherwise our table now looks great, and thank you for the post!