This project was built and designed by Jay Bates. It’s a thoughtful and detailed firewood rack design that blends classic joinery techniques with CNC precision, making it both functional and visually striking.
Jay revisits the strength and beauty of traditional woodworking, exploring different joint styles and combining them with modern methods. The result is a firewood rack that’s not only sturdy enough to handle heavy loads but also refined enough to elevate any outdoor space.
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Starting with an Ambitious Idea
Jay sets out to build a small batch of firewood racks using dovetailed halflap joints, keyhole slots, and traditional mortise and tenon elements. Inspired by his earlier work on a massive workbench, he approaches this project as a blend of craftsmanship and efficiency.
He prefers larger builds over small, detailed projects because they offer more room to experiment and allow for refining techniques over multiple iterations. This firewood rack serves as a proving ground for those ideas.
Understanding the Halflap and Dovetail Connection
One of the primary joinery methods used here is the dovetailed halflap joint—a strong, self-locking joint that adds both durability and a classic aesthetic. Jay explains that while it may look complex, the joint is accessible for most woodworkers with a bit of planning and practice.
Halflap joints are a great introduction to joinery, offering strength and simplicity. By adding a dovetail shape, Jay increases the mechanical grip of the connection, which helps reduce the need for glue or hardware in some parts of the build.
Preparing and Milling the Lumber
Jay begins with standard 2×4 construction lumber, taking the time to cut pieces to length and remove the rounded edges. This step is critical to ensuring square joints and clean edges during CNC machining and assembly.
Even though the pine has some bowing and twist, proper layout and clamping mitigate these imperfections. Milling the lumber first ensures a consistent foundation for all of the joinery work that follows.
Testing Router Bits for Cleaner Results
Before jumping into mass production, Jay experiments with different router bits to find the best cut quality. He starts with a half-inch upcut bit, which performs decently but leaves noticeable tear-out when cutting across the grain.
Switching to a compression bit dramatically improves the results. While pine can still produce some “fuzzies,” the compression bit provides a smoother edge and cleaner final appearance, especially when climb cutting is used.
CNC Meets Classic Joinery
One unique aspect of this build is Jay’s use of CNC technology to cut the dovetailed halflap joints and mortises. While traditionally done by hand, the CNC brings accuracy and repeatability—ideal for batching out multiple racks.
Jay embraces the hybrid method, showing how modern tools can be used to speed up traditional techniques without sacrificing quality. It’s a practical approach that balances the best of both woodworking worlds.
Dry Assembly Without Glue
After the pieces are machined, Jay assembles the side frames without glue to test the strength and fit. Even without adhesive, the joints hold tight thanks to the dovetail shape and accurate machining.
This dry-fit test highlights the structural integrity of the design. It also gives Jay a chance to inspect grain orientation and adjust anything that may affect the long-term stability of the rack.
Color and Character with Milk Paint
With assembly complete, the final touch is a coat of Tuscan red milk paint. This deep, rustic color not only matches Jay’s outdoor kitchen but also gives the firewood rack a vintage, time-worn feel.
In a fun twist, Jay’s daughter joins in to help with the painting process. It’s a moment that adds meaning to the build and reinforces the joy of involving family in the shop whenever possible.
Function Meets Design
Once the paint is dry, Jay loads up the firewood rack and steps back to admire the final product. The clean joinery, deep red finish, and balanced proportions make it feel more like a piece of outdoor furniture than simple storage.
The design isn’t just strong—it’s attractive and adaptable. Whether placed on a patio or by an outdoor fireplace, this rack serves a clear purpose while still showing off quality workmanship.
Takeaways for Any Woodworker
Jay emphasizes that experimenting with joinery is part of what keeps woodworking engaging. Even though dovetails are a hallmark of fine furniture, using them here in a utilitarian project proves that functional builds can still showcase craftsmanship.
He also notes how a good design can be repeated, adapted, and scaled once the workflow is dialed in. This project serves as a great example for woodworkers looking to batch-build for sale or organize their outdoor areas with style.
Please support Jay by purchasing his plans here: Jay’s Custom Creations.
Matt’s Take
These are my personal thoughts and tips based on my own experience in the shop. This section is not written, reviewed, or endorsed by the original creator of this project.
The dovetailed halflap joint is one of those connections that really shows off what’s possible when you combine traditional joinery with modern precision. What strikes me about this approach is how the CNC removes the intimidation factor from cutting dovetails — you get that classic mechanical strength without spending hours with a handsaw and chisel. The self-locking nature of the dovetail means these joints will actually get tighter over time as the wood moves.
That router bit testing phase is worth paying attention to. Pine can be tricky to machine cleanly because of its grain structure and resin pockets. A compression bit is definitely the way to go for this kind of work — it gives you that crisp edge on both the top and bottom of the cut. If you’re working without CNC, a sharp shoulder plane can clean up any fuzziness after routing.
The milk paint finish is a smart choice for outdoor furniture. Unlike film-forming finishes that can peel and trap moisture, milk paint penetrates the wood and breathes with seasonal movement. Plus, it ages beautifully — any wear just adds to the character rather than looking like damage. That Tuscan red will mellow into something even more appealing over the next few seasons.
Building multiples is where this kind of project really shines. Once you’ve got the setup dialed in and the workflow smooth, each additional rack gets faster and more refined. It’s a great way to justify the time spent on jigs and test cuts.