Transform reclaimed barn wood into a charming rustic bench with this easy-to-follow tutorial. Perfect for beginners, this project combines functionality and farmhouse charm, adding warmth to any space.
#RusticBarnwood #DIYBench #UpcycleFurniture #FarmhouseStyle #Woodworking #HomeDecor #Handmade #BarnwoodProjects #FurnitureMakeover #OutdoorFurniture
#RusticBarnwood #DIYBench #UpcycleFurniture #FarmhouseStyle #Woodworking #HomeDecor #Handmade #BarnwoodProjects #FurnitureMakeover #OutdoorFurniture
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00:00In this video, I'm going to show you how to take reclaimed wood and make a rustic bench like this.
00:04Alright, so the first thing I'm going to do for this bench is get these boards ready to get glued up.
00:09So, because it's bondwood, I'm going to run them over real quick with a metal detector.
00:16Nothing that brightens my day more than running a nail through my planer.
00:20So, with Bondwood, the reason we use it is because it's got a lot of cool characters, it's got cool history, it's got cool saw marks and everything.
00:25But, it's always, you know, uneven and twisted and stuff like that.
00:28When I'm looking at the boards, what I'm trying to find are the surfaces that I want to eventually be on the top or the exposed ones.
00:34And everything else is going to basically get planed or mitered or cut to something that's usable and workable.
00:42Carpentry and woodwork, to a large measure, especially for the vast majority of projects, really comes down to getting 90 degree angles.
00:49So, what we're trying to do is find in these boards some place to get some nice flat 90 degree angles and then mate it up.
00:55And then the objective with the barnwood is to not have at least a third side or sometimes two sides that also show some of the character in the barnwood without compromising your ability to have good joinery.
01:07So, I'm going to have basically three pieces that go inside this benchtop.
01:11Actually, that's a lie. I'm going to have four pieces.
01:12What I want to do is have two full pieces on the front and the back and two pieces in the middle that are made up.
01:21I have longer boards for no other reason than I kind of think it looks cool and it's fun and I'll put a bow tie in there afterwards and I can kind of show you how we do that.
01:29A glue up that has some boards that aren't full length.
01:31Because the reality is that sometimes with barnwood, you don't have boards long enough to make your table or your bench and so you can splice them in.
01:40So, first thing I'm going to do is go over to my planer jointer and I'm going to take out the face that I want to keep.
01:45So, in this case, this board right here, this top is what I want to keep.
01:48The bottom side was quite a bit more weathered and the saw marks weren't showing up quite as well.
01:53And I don't know if you can see this through the camera right there, but there's some really nice circle saw marks here.
01:58So, I'm going to flip it this side down across the planer on the top until I get it where the blade is touching somewhere all the way along.
02:09Or at least I know that it's a flat enough surface that when I flip it over to go through the thickness planer, then I know it's not going to twist and bend as it goes.
02:17So, I'll do that really with all of these, find the size that I want to use, give it a little bit of a plane so that we can see the character.
02:26And that's also one way that I get to manage how much the character is and isn't seen by doing that.
02:31So, let's head over to the planner.
02:34Wait, wait, before we head to the planer, we're going to cut these down to size.
02:37I want this eventually to be 70 inches long, so I'm going to leave it a little bit long, maybe cut them at 72 or something like that.
02:42No sense running more through the planer than we have to, so we'll kind of cut it down to size real quick on the chop saw.
02:47The joint here on top, the idea with it is that you run a board along the top, and you can see how when I push this right now, it's not level.
02:57So, as long as I hold this board uniform as it goes across, it will start taking off in a flat plane on the bottom side of this board.
03:05And if I can continue to do that by either holding it against the fence or keeping it in one direction, then I'm going to end up with a flat surface on the bottom, which is really what my objective is.
03:14Or a flat-ish surface, because this bottom side, well, what's bottom right now, will eventually become the top side of my bench top.
03:23The whole objective is just to get a flat or somewhat flat surface on the bottom here.
03:26You can see here, all that did was start to take off pretty much this entire side here, and then this back side as well, which means this side here is high.
03:41But now I'm going to continue to take pieces off.
03:44Well, it's going to keep on taking off this edge and this edge, and eventually both of these edges will be somewhat flat.
03:51So, by the shape of the board, you can kind of tell there's a bit of a dip in the center.
03:54And I'm going to keep that because I want to preserve those saw marks.
03:57But if I can get both these sides of the board to be uniform and flat, then when I go to flip it over and plane this side, even though this center is concaved, I'm still going to have it traveling through, holding on to those two outriggers, basically.
04:11Okay, now here's the next board that I'm doing, and you can see it's a little bit different.
04:14So, the planer is taking off, you know, almost halfway through the board on the front here.
04:20It's just touching all the way along the middle here and at the back.
04:24So, this is actually a pretty flat board to start off with.
04:26I'll probably just have to go over it one more time to make it somewhat flat.
04:31And then, actually, this board will end up leaving quite a bit of character.
04:33Sometimes the boards, depending on how they're shaped, you end up taking off the vast majority of the characters.
04:38So, it's kind of important to choose somewhat flat boards to start off with.
04:43But with Barnwood, you kind of hit what you can get.
04:47There's the second pass.
04:48So, I'm actually pretty happy with that.
04:49There's still a little bit left to go here, but well more than half of the board is on that plane, and way over half of it here.
04:58So, when that gets turned over, and it's being held down by the planer as it goes through,
05:03I'm not too worried about it flipping and moving and bending as it goes through.
05:06And I've preserved some of the character, and I've got a flat base to work off of.
05:09Okay, so here's the bottom side after they're all planned off.
05:16We're looking really good.
05:18We've got a really, like, we have equal thickness boards all the way across.
05:23But now you can tell the problem is, is that our joints obviously aren't going to match up.
05:28So, what we want to do is use this top flat part as our reference plane, and we want to start cutting 90s off, well, not all sides, all the middle joints.
05:39Because I want to leave the live edge on the outside of both sides, because that's, I kind of want to expose that.
05:46But now that we've got one flat edge, you know what I'm saying?
05:49Like, now it's easy for us to cut a 90, as long as our saws are cut at 90.
05:52On the bottom side of the board, which is now going to be the top, we've left some of the characters and the saw marks.
05:58Okay, so with carpentry or woodworking, there's actually, in many cases, a lot of ways to get the results you're going for.
06:05And it's more important to understand the, likes, concepts and objectives than it is to know exactly the tool that you have to use.
06:13And so, when you're looking at wood plans, or when I show you how to build something, you don't have to have all the tools that I have, right?
06:19Like, guys who were building furniture 100 years ago didn't have a lot of this stuff, and they still did a good job.
06:23It took a whole lot longer, but if you don't have all the tools, that shouldn't stop you, that shouldn't discourage you.
06:29What we're trying to achieve here, as I've already mentioned before, is just a 90 degree angle, so that when we go to glue up, everything works really well.
06:36So, I've used my joint to get my boards a uniform thickness, and now I want to use this flat side to basically somehow make a perfect 90 degree on one side, so that's when I go to, well, sorry, and then I'll use that 90 degree to also create my other parallel 90 degree on the other side, using the same bottom as my reference point.
06:57And there's a few ways to do it. In past videos, I've shown you how to use a table saw, I've shown you how to use a track saw, and now that's kind of what one of these jointers, planer jointers are for.
07:04I'm going to show you how you can hold, like, what I'm going to do here is set this fence so it's at 90, I've already set it, and I'm going to hold against it, and then the same principle applies.
07:13I'm going to run it across these blades, and if the board was bowed like this, then it's going to take off the front and the back, and I'm going to keep on going over it, and as long as I'm holding it up against the fence, it'll continue to take off the front and the back until we're getting a perfect cut all the way along.
07:28After I've got one flat side, one straight side, and a 90 degree on one side of the board, I'll actually use the table saw to cut the other side.
07:36Flipping it over and doing the exact same thing on the other side, especially with barn wood, isn't the greatest idea, because the board is not uniform, and it might be thicker on one end than on their end, you are going to run it across, and you are going to end it with a flat line, but that flat line isn't necessarily going to be parallel to their flat line.
07:53So once we've got a flat, perfect, straight line here, then going over to something like a table saw, where you hold it up against the fence, then you're going to get a very predictable and parallel line to this line.
08:06That's it. Now we've got a nice, perfect 90. I mean, it's a great tool to have, but if you don't have one, it's not the end of the world.
08:26So I'll do that to one more, and then we'll move on to the track.
08:28So now with these pieces, we've got some lumpy we can work with. I didn't show you, but I cut the other side off on the table saw, and then I ran it through.
08:34And now we've got two boards with some characters on top that are perfectly straight and parallel, and will be a really good glue-up.
08:42Now, with these two boards, these are going to be the outsides, or the front and the back of my bench, and I want to leave one side live.
08:51I mean, I want to leave it so that it has some character.
08:53So I'm not going to do the exact same thing that I did here, and using the joiner isn't really the greatest idea,
08:58because for the same reason that I said it's not great to join both sides if you don't know that the boards are uniform,
09:04if I go now and plane one side off that's perfectly flat, and I can, and it's straight,
09:11let's say that this side over here was five inches, and this side over here was four and three quarters,
09:15and there was a similar thing on the other board, then I'd end up sorting with a weird shape.
09:19The glue-up would actually work. Like, I would have 90s, and they would be straight,
09:23and so everywhere that I had a glue-up would be fine, but I would end up with sort of a, what is it called, a polygon, or a trapezoid, or I don't know what it's called.
09:29Some irregular shapes. So what I'm going to do is use the trash saw, I'm going to decide which side I want to keep,
09:36and then I'm going to measure off of that, and I'm going to cut my straight line.
09:40That way I know that the two ends of my board, on both sides, are going to be the right distance.
09:48So my, my, my bench top, at the two ends, are going to be uniform, and it's going to be square-ish.
09:55It might, like, the board might bow out a little, or it might even curve in a little bit,
10:01but it's going to be a square unit, if that makes any sense.
10:03These boards are pretty straight, so I'm not expecting, like, a huge bow, but, yeah, you get what I'm saying here.
10:09So you could try and do it on a table saw, but it's kind of tough if your boards aren't straight.
10:14I have a slide table saw, and that works really great, or you can use a track saw, and that's usually one of my go-tos.
10:20I'm going to measure back four and a half. I'm going to clamp it down with me, with my clamps.
10:26The track saw is great because it can, it greatly reduces the amount of user error.
10:32So if I try to cut a straight line with my saw, by myself, I don't care how good you are,
10:37you're still going to end up with some bucks and kicks.
10:39It's going to hit a, a knot. It's going to twist a little bit, and you're not going to get a perfect straight line,
10:45and it's going to kind of break out a little bit.
10:47So the track, really, all it does is it holds it straight.
10:50It helps it to cut in a straight line, and because this is on here, it also,
10:53it also prevents, like, the chipping and the cracking of the board as it goes along.
10:57So definitely a great tool to have.
10:58Yeah, they're a little bit expensive, but you don't have to have one,
11:02but I definitely recommend you get one if you can.
11:09Thank you.
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