This project was built and designed by Jonny from Jonny Builds. It’s a striking live edge bench made from western red cedar and finished with custom welded steel legs, blending natural wood with modern, industrial metalwork.
Part of a creative collaboration with Mike from Industrial Maker, this bench represents Jonny’s take on a shared design challenge. The result is a unique and functional bench that highlights woodworking, welding, and thoughtful design.
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Starting with the Slab
The core of the bench is a live edge slab of western red cedar, locally sourced and dried for nearly ten months in Jonny’s shop. This waiting period allowed the slab to stabilize, reducing the risk of warping or cracking after the build.
Cedar’s natural durability, color variation, and smooth workability made it a great choice. The slab retained its organic live edge on both sides, adding character while keeping the design grounded in nature.
Flattening with a Router Sled
To prepare the slab, Jonny used a custom router sled to flatten both surfaces. This method involved shimming the slab for level and running an aggressive surfacing bit in multiple passes.
After flattening the underside, the slab was flipped and leveled again for top-side flattening. The result was a perfectly flat and parallel surface while preserving the natural shape of the edges.
Smoothing the Live Edge and Laying Out the Legs
With the slab prepared, bark removal was handled using chisels and an orbital sander. Cedar bark is relatively easy to remove, and this step revealed clean, curved edges.
Jonny then marked leg positions using a speed square, measuring a few inches in from each end. This gave the legs a proper inset and balance between support and visual appeal.
Building the Steel Legs
The steel legs were constructed from 1×2-inch rectangular steel tubing, cut using a cold-cut metal saw. Each piece was mitered at 45 degrees to form clean corners for welding.
Before welding, the mill scale was removed from the steel for better weld penetration. Jonny used magnetic clamps and a custom MDF jig to keep pieces square while tack welding.
Once aligned, he used a MIG welder to complete the full welds with argon gas. The welds were then ground flush using a flap disc for a smooth, finished look.
Supporting Structure and Design Details
Additional steel elements were cut and added to fit underneath the slab. These included spacer blocks to support the slab from beneath and a vertical center brace, which served more as a visual element than a structural one.
To ensure accuracy, clamps were used as stops during assembly. After all pieces were welded, the final leg frames were symmetrical and sturdy, ready for finishing.
Finishing and Distressing the Legs
Before attaching the legs, pilot holes were drilled for mounting bolts. The bolts were zinc-coated but had their finish removed with muriatic acid for a raw, aged look.
The legs were painted in a rich blue color using Montana spray paint. After drying, Jonny used a combination of sandpaper, a chisel, and steel wool to distress the paint and give the legs a worn, vintage character.
Washer and bolt heads were also treated with steel blackening fluid for a darker, aged appearance. A spray-on varnish was applied to seal the legs without adding gloss or shine.
Restoring the Cedar Slab
Several knots and voids in the slab were filled with a two-part epoxy. Once cured, the epoxy was heated and scraped flat with a chisel, then sanded smooth with the rest of the surface.
The final sanding revealed striking color patterns in the cedar, including soft pink and purple tones that had been hidden beneath the surface. This brought out the slab’s natural beauty and helped balance the bold metalwork below.
Assembly and Final Finish
The bench was assembled by sliding the slab between the steel legs and securing it with bolts through the pre-drilled holes. Washers were used as needed to fine-tune the fit and ensure tight contact without damage to the wood.
A water-based polyurethane topcoat was applied to the cedar, protecting it from moisture while preserving its natural matte appearance. This finish helped highlight the contrast between the bright cedar and the distressed blue steel.
A Modern Take on Functional Design
This bench is a strong example of blending materials and disciplines. The natural edge of the slab adds warmth and texture, while the painted and distressed steel gives the piece an industrial edge.
The bolt-together design also allows for easier transport and disassembly—an often overlooked but practical element in large furniture builds. Together, these details make the bench both attractive and functional.
A Collaborative Challenge with Creative Results
This build was part of a design challenge with Mike from Industrial Maker, where each creator made their own version of a bench using similar materials and goals. Jonny’s bench leaned into clean lines, creative finishes, and practical joinery.
For those interested in combining wood and metal, this is a solid entry point. The project introduces basic welding, epoxy use, slab prep, and finishing—all skills that carry into future builds.
Please support Jonny by checking out his website here: https://www.jonny-builds.com/.