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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00:00Okay, now those are all done. We've got something kind of looking like this. The
00:06idea is these will be the legs. I'm going to cut these and they're going to sit on the outside, here, and here, then we'll have the other two pieces that go there and there.
00:22It's obviously going to be bigger. So what I'm going to do now is go and cut all
00:25these to the final dimension that I want with 45 degree miters on all the pieces and
00:31then we can build that, set it in place, and then fasten it all together with glue and
00:37some, I use some screws, like I pre-drill and use screws on the inside, and then it
00:41comes and grabs onto those and sucks everything together.
00:46Okay, just quick to show you here. So no nails, no screws, no biscuits, no nothing,
00:52just a nice tight tight joint, and then this strap just holds everything together nice and easy.
00:58If I wipe the glue away, you can see we've just got a really nice tight joint. Since we've got
01:04our miters all set right, like it can't help but pull everything together
01:09into the 45s and make us a 90 degree angle. If we grab this square here and set it on,
01:16we'll see that we've got perfectly 90. Like there's not even, if your angles are right and your boards
01:21are square, then you can't help but get things all 90 degrees.
01:31Okay, it's tomorrow. I got the same hat with a different shirt on today. This has set up nice,
01:36the glue is all dry, so I'm going to unclamp it, we'll clean up all the glue, we'll give it a nice
01:40sand over the entire thing, and then I'm going to put some black walnut stain on it and give it some
01:48color.
01:55Okay, before I stain here real quick, let's just review or critique what I've got going on here.
02:02As with all the videos you've seen, like I'm looking for nice tight joints, I'm looking for nice tight
02:07miters, I'm looking for good glue ups, you know, like I want nice straight lines,
02:13and mission accomplished here. Okay, time for some stain, I'm going to use Watco Danish oil,
02:17this is the black walnut, it's the dark stuff. This Watco oil is Danish oil, it's basically a mix between
02:23an oil and a polyurethane, it's trying to be a hybrid and kind of get the best of both worlds.
02:28So it is a sealant, it does soak into the wood, and it's good, I like it. In this case, I'm really only
02:35using it to make this dark, so then I can put white paint on top of it, and then sand it and
02:41reveal some of the dark underneath. So the criteria I'm looking for is something dark, something kind
02:45of easy to apply. And because it has that mix of the polyurethane with it, I find that when I use
02:51this stuff as opposed to a stain, when I go put the white paint on top, if this stuff is dry, it doesn't
02:57seep through, right, like it doesn't leak and cause problems. In that case, you usually would put on a
03:01stain and then you put a polyurethane on top, and then you put the white paint on top of the polyurethane
03:06to stop the oil from leaking through into your paint. And I've had good luck with this stuff. So I'm
03:11going to brush this on.
03:19Okay, glue is all set up on this bench top. We're going to unclamp it and we're going to sand it all
03:24down with an 80 with my trusty BO 6050J Makita Sander.
03:32Okay, so I've unclamped everything. It's all looking really good. That's the top side,
03:35this is up at the bottom side. I do want to have a nice flat bottom. It's really close right now.
03:40I am going to square up this bottom kind of quick. So there's a number of ways of doing this, but really
03:44two that you might have. One is going to be one of your hand planes and you're going to plane across
03:50the entire thing. Or basically use the electric version. You've got a bigger, they're both flat
03:56blades. Depending on the size of your hand plane, it may or may not be that size. This one's got two
04:02of them on the inside and basically you're just using battery power to spin that blade as opposed
04:06to pushing a flat blade across. Some will contend that this will give you a better finish and I
04:11won't argue with that, but this is the bottom of the board and really all we're trying to do is take
04:15off enough material that everything's nice and flat. So there's just a tiny bit of difference in some of
04:20these joints right now and cleaning up the glue. So I'm going to set this on the second setting and
04:24just kind of work my way across the entire board from front to back and that's going to give me the
04:30flat enough surface that I need to either put through the planer or just flip it over and it's
04:34the underside anyways. I could sand it after that. You can use this. It takes a little bit more time.
04:39Some people that are purists prefer it. They think that it's better. You're going to get a workout which is
04:42always good. You can use some counters, but I'm going to use this this Makita unit right here. I'll have a
04:47description below if you want to check this one out. I use it quite often.
04:57So I'll do a first pass like that. It kind of gives me a reference point and I'll just go right
05:01beside and just keep following my way across.
05:06So yeah, now I'm going to sand both sides of this. I'll flip it over, sand the back side of it
05:10to get it flat and then I'm going to go through and do kind of what I explained before and sand this top down.
05:18All right, so on this bench top we've got these two boards in the middle that are actually joined
05:22and they're glued and they're solid and they're good. I'm not that worried about them, but I am going
05:27to put a type of bow tie in there. So there's Slab Stitcher. They make this pretty cool product
05:33where you can have bow ties or X's or they've got a bunch of different shapes now. Basically it's just a
05:39little jig and a brass bushing type deal and their router bit and you can router out their CNC cut
05:47bow ties. They work awesome. If you set it up right, they go in, they're a huge time savings device
05:54and they look really good. So the two reasons to put bow ties in, one is to strengthen a joint or to
06:00strengthen a crack or to prevent something from cracking any further to stabilize wood and second
06:03it's just to look good. It's just aesthetics and in this case it's kind of playing both functions.
06:08So really it's pretty simple. You've got to put this bushing in because this is what kind of holds
06:15the router bit nice and steady. All right, so that goes in there. I'm going to swap out my router bit.
06:26That fits back over top and we're going to want to set the depth. So if you look here, the depth of
06:36the bushing right now is just under the depth of this little plexiglass deal. So we want to set the depth
06:45of the router bit to be just this like exactly the same size or the same depth as the cutout
06:54or maybe just a little bit less and that way this will sit up kind of proud and you can sand it off
06:59flat afterwards. So what we're going to do is we want to set
07:06this piece because that's what it's going to be sitting on on top of whatever you're cutting through
07:11and you're going to set the depth so that router bit just touches the top of the wood.
07:21And like I say, maybe just a little bit less so you give yourself a little bit of room
07:25to sand that off afterwards. And now when that's sitting down flat, then we've got the depth that
07:34accounted for. So I'm just going to place this on here kind of how I want it. I'm going to clamp it
07:38down. We're going to router this baby out and then we'll clean up the edges with a chisel
07:45and we can set that X in place. Like I said, they do have bow ties and they're cool too. I just
07:49haven't done an X yet. I ordered them a while ago, so I want to do an X.
07:52Okay, so now we're going to move on and put a filler across this entire deal. The reason I put
08:05the filler on is because it uniformly fills. So let me step back really quickly. At this point,
08:10you can come and just sort of spot fill all the holes, spot fill some of the cracks, but when you
08:16when you do that, you kind of end up with sort of a sploshy looking deal. So I get wood filler
08:23that's usually for floors, for filling floors, and I trowel and flood coat the entire thing and push it
08:28down into every one of the cracks and every one of the holes because it's barn wood. It's got a lot
08:31of those saw marks and everything. There's two reasons for doing that. One, it helps to level
08:37everything out. And two, where all the character marks are, that ends up being a uniform color and
08:41looks kind of cool afterwards. So normally I use this Woodwise patch filler. It's great. I love it.
08:45There's no, there's no reason that I don't, but I was on Amazon the other day and it was,
08:50I was ordering some more of it and this came up as another recommended product and it said
08:54good filler. And I thought that's a cool name. So I want to try it out. So I ordered some and I got it
08:59in today. And so I have opened it up and it says trowel ready and it looks trowel ready. And so normally
09:07it would be wise to kind of do a test piece, but I'm going to just do what Shania Twain says and
09:13bet on love and let it ride. We're going to put this all over it and see what happens. It looks
09:17black. It looks good. It looks very similar, maybe a bit darker. So I'm going to slop some on there.
09:22You're going to see me trowel it off and spread it out super, super thin in the areas where there's
09:28thicker or not thicker, but deeper grooves. I, with this stuff, I typically have to come back and refill
09:34it. I imagine it'll be the same with this. This is a water base. It says it's also, you can stain it,
09:38you can paint it, you can sand it. It's got a lot of the same characteristics and I'm going to give it
09:43a try. For those of you that want to know, this is kind of what it ends up looking like.
09:51You might think that you destroyed your whole tabletop or bench top, but wait till the next step.
10:00All right. I went and had some lunch and this black stuff is all dried up now. Before I put this stuff on,
10:05I did actually go into trim it. I didn't tell you guys that nor I didn't film it, but remember how I
10:09left it long before I put this stuff on. I cut it down to 70, which was where I wanted it, just on
10:14the chop saw and then I sanded the size. So I've got a 150 on here now. I'm going to sand the whole
10:19thing down, leaving it as flat, you know, relatively flat so that it basically creates a nice flat surface.
10:24Another reason why I like this is a six inch instead of a five inch. So you've got kind of a bit more of a
10:28footprint. We're going to sand it all down and kind of see if any of these deeper crevices and cracks need
10:35some more. And if not, then I'll probably go to 220 and then 320 and then we can put our finish on.
10:45Sanding, now we're left with a really nice smooth surface. You know, like one of the major things is
10:52we want to cover up and plug all these cracks and holes. This is going to be a bench at a kitchen
10:56table and people might wipe their kids might wipe their spaghetti hands or something down there. So I
11:01don't want anything down in the cracks. I want a nice smooth surface. I don't want slivers in anybody's
11:04butt. And everywhere where the black stayed in these saw marks and cracks and everything,
11:09it's all a uniform color. Now it is going to get, there's our nice X, there's that big long crack.
11:14It is going to get some, some color now, but oh yeah, I forgot to tell you, there was a crack here
11:20in the end that was kind of going all the way through on, on just the end of it. So I put in
11:25one more bow tie. In this case, like it does look cool and everything, but it really was to help that
11:31crack, not want to do a whole lot more than it had already done. Even though this is dry wood,
11:36that's a real practical use for, for one of those bow ties. So this one has one of those bow ties
11:41and that X in the middle that, that helps those two boards stay together. Okay. So I'm really happy
11:45with where this one is at. I went up to 220. That was about enough. I didn't feel like I needed to go
11:49any more than that. I'm going to use Osmo on this one, this Osmo wax or hard oil wax, I guess it is.
11:55And pretty easy, crack it open. You mix it up and then I'll rub it in. It penetrates down into the,
12:02into the wood. It really brings out a lot of the character of it. It is a, it is a color.
12:07It's a little bit lighter than the last one that I did in the last video. And we rub it on and then
12:12we'll come back afterwards and take off all the excess and kind of just buff it a little bit.
12:17And that's it. And we let it set up overnight.
12:25Okay. So apparently the video of me painting this didn't really work. It wasn't that complex. I basically
12:29used white paint. I brushed it all on. I did two coats. I actually wanted this one to be quite
12:34a little bit thicker. Like I wanted the paint to be white and the paint to be thick. And now I'm
12:39going to go with my sander. You can do it by hand. You can do it with an orbital sander. I'm going to
12:43do it with mine. I've got 150 grit on here and just lightly, I'm going to start passing over it and
12:49paying attention to wherever the corners and the edges are and sometimes in the middle and just get
12:54some of that brown to sort of show through until it looks like it's kind of, you know, rustic.
13:05So you can kind of see what I'm doing there. Just starting to make the brown from the stained
13:10wood kind of show through in some areas. I don't want it to be super regular. Like it might look like,
13:16you know, more people walked and brushed against it on this side than that side. If you do it all
13:20entirely uniform, then it kind of looks manufactured. So you're just kind of doing it a little bit
13:25randomly, but obviously paying attention to the parts where normal rub and wear would have happened.
13:30Okay. So this is our top. I've got it flipped over. I didn't video it, but I did put polyurethane on the
13:36bottom of this just to, just to seal it. It doesn't have any color on it, but it's the bottom. People can't
13:40see it. Now we're going to put our base on it. We'll center it.
13:52And I'm going to use these L brackets, angle brackets. We're going to, I'm going to put them
13:56into the base first and I'm going to leave them just above the bottom of this top. So then when I,
14:04when I go to screw it down, it actually really sucks it into it. You don't want to do a whole bunch
14:08or you twist the whole thing out, but I leave it up just a hair. And then when I go and screw down
14:12into the top, like I say, just, it just sandwiches everything down really nice.
14:16I will pre-drill before and then I'll sink the screws in. Pretty simple deal.
14:29And I'm going to put one more finish coat on top of here. I did the stain as you saw,
14:34I actually did put a top coat on. So with this Osmo, you do your stain and then you do a top coat
14:38and I'll do two top coats on this. So we'll roll it on. And then I just like to kind of buff it out
14:44with the rag. Okay. So what I've got here is the Osmo Poly X. I put it in this tray with a foam roller
14:50and I've just rolled it and rolled it and rolled it until it's uniform across the entire deal. There's
14:56not a whole lot that you have to put on. And then I'll just, I'll actually, well, I guess I'll start
15:01on the side here. And I'm just going to go back and forth over this whole deal, spread it out.
15:08Thin is good. There's going to be more than enough on this roller.
15:14I'm going to go back. What do we got there? I'm going to go back and forth this way.
15:18Like that. And then I'm going to back roll lightly the entire thing. Just overlapping a little bit.
15:32That'll give me a nice, even coat. I'm going to let that sit for a little bit. And then I'm going to
15:39come back with a clean rag and then just wipe with the grain and level it all up. Okay. Now I'm going
15:45to take a clean rag and this is, I'm just basically wiping off the excess. I'm just going to go along
15:52with the grain all the way down. Nice and even. We're just kind of smoothing it out and taking off
16:02the excess. Just like that. And now we will let that stuff do its job and set up. And this bench is done.
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