This project is designed and built by Taylor from DesignedByTaylor, and it’s perfect for anyone wanting to add a unique touch to their space. Follow this step-by-step guide to make your own stunning table from barn wood!
Materials and Tools Needed
- Barn wood (or your choice of wood)
- Titebond III wood glue
- 3/8 inch dowels
- Pipe clamps
- Orbital sander
- Wire brush
- Planer
- Rockler Corner Key Jig
- Flush cut saw
- Varathane matte finish
- High-quality bristle brush
- Sandpaper (80, 150, 240, 320, and 400 grit)
Step 1: Choose Your Wood
Start by finding a good piece of wood. Taylor sourced barn wood from a local farm, which he planned to use for multiple projects. Cut both ends off and measure what you have left to work with.
Step 2: Cut the Wood
Make two forty-five degree cuts from the middle of the board. This will give you two leg pieces on either side and a top piece. After cutting the top piece, make another forty-five degree cut on each leg to reverse the direction of the angle. This creates a seamless waterfall effect when the table is assembled.
Step 3: Prepare the Wood
Remove any loose bark from the pieces. Now it’s time to sand each board using an orbital sander. Start with 80 grit, then move to 150 grit, and finish with 240 grit for a smooth feel.
Step 4: Clean Up the Surfaces
After sanding, use a wire brush to clean out any loose material in the areas the sander couldn’t reach. The faces may be rough from the miter saw, so use a planer to smooth down the connecting faces. Perform a test fit on your workbench to check alignment.
Step 5: Apply Wood Glue
Once the alignment looks good, apply some Titebond III wood glue on the connecting faces. Let the glue absorb into the wood for a few minutes before applying a second layer for a stronger bond. End grain glue joints can be weak, so this step is crucial.
Step 6: Prepare the Dowels
While the glue dries, cut a 3/8 inch dowel into four inch pieces for the joint. Test the alignment again and mark where the dowels will go. Use the Rockler Corner Key Jig for easy miter joints. Clamp the jig to the workpiece and drill the holes for the dowels.
Step 7: Assemble the Table
Once the dowels are in place, clamp everything together with pipe clamps. Be careful not to cover the dowels. Clamp for a full 24 hours to ensure a proper bond.
Step 8: Final Touches
After 24 hours, remove the clamps and use a flush cut saw to trim any dowels that are sticking up. Fill any gaps in the joint with a mixture of wood glue and sawdust. Let this dry for a couple more hours.
Step 9: Sand the Ends
Sand the ends of the piece using 80, 150, and 240 grit sandpaper. Repeat the same process on the other side of the workpiece for a consistent finish.
Step 10: Apply Finish
Taylor used Varathane matte finish for this project. It’s recommended to mix gently before use to avoid bubbles. Use a high-quality bristle brush for the best finish. After the first coat dries for 24 hours, sand it down with 320 grit sandpaper by hand to avoid removing too much of the finish.
Step 11: Final Coats
After vacuuming the piece, apply a second coat of finish and let it dry for another 24 hours. Once fully dry, use 400 grit sandpaper to smooth it out one last time before applying the final coat. Let this coat dry for another 24 hours.
Enjoy Your Unique Table!
After all that hard work, your rustic entryway table is complete! Taylor is thrilled with how this piece turned out, highlighting the rich color and smooth texture. Remember, it’s not perfect, but that’s what makes it one of a kind.