This project was built and designed by Caleb from YouCanMakeThisToo. The bench features traditional wedged mortise and tenon joinery, combining strength and visual appeal in a timeless woodworking design.
It’s a detailed project that highlights the precision of hand-cut joinery while incorporating both machine and hand tool techniques. Caleb shares not only his build process but also helpful advice for anyone looking to improve their joinery skills.
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Selecting and Milling the Lumber
Caleb begins the project by selecting durable hardwood, emphasizing the importance of both strength and appearance in furniture pieces. For beginners, he suggests using S4S (surfaced four sides) lumber, which comes pre-milled and simplifies the process.
After choosing the boards, he breaks them down into rough lengths and begins milling. Using machines like a jointer and planer speeds things up, but he notes that similar results can be achieved with hand tools. He’s also produced a separate series on how to substitute machines with hand methods, making this build more accessible.
Gluing Up Panels
The benchtop and legs are too wide for a single board, so Caleb performs several glue-ups to create larger panels. He takes the extra step of hand-planing each joint before gluing to ensure tight seams and minimal gaps.
To keep everything aligned during glue-up, Caleb uses clamping cauls. This technique helps distribute pressure evenly and minimizes panel bowing—an important detail for producing clean, flat surfaces.
Crafting the Joinery
The signature element of this bench is the wedged mortise and tenon joint. Caleb begins by cutting tenons with clearly defined shoulders, which help stop the wedge from pulling the tenon too far through the mortise.
He uses a marking gauge to ensure consistent tenon sizing, then removes material to create clean shoulders. Each tenon also receives a small drilled hole to accommodate the wedge—a clever touch that makes the joint stronger and more visually interesting.
Cutting Accurate Mortises
For the mortises, Caleb uses different methods depending on the part of the bench. On the legs, he drills out the waste material at the drill press, then cleans up the sides with chisels for a snug tenon fit.
On the benchtop, he switches to a palm router for removing the bulk of the material and then squares the corners with a chisel. This technique helps ensure that the two mortises stay perfectly aligned while reducing the amount of chisel work required.
Test Fitting and Practice Runs
Before committing to the actual parts, Caleb practices the wedged joinery on scrap wood. This gives him a chance to refine the technique and reduce mistakes—a smart tip for any woodworker working with traditional joints.
He double-checks all tenons and mortises before assembly, making small adjustments with hand planes and chisels. Taking this extra time at the fitting stage makes the final glue-up much smoother.
Preparing for Glue-Up
With all joinery ready, Caleb preps the surfaces for glue-up by smoothing all sides one last time. He notes that it’s far easier to do this before assembly, especially in tight corners or between joints.
Though he mostly uses hand tools for shaping, he switches to a sander at this point for final cleanup. It’s a reminder that there’s room for both hand and power tools in woodworking, depending on what the project requires.
Final Assembly and Wedges
During the glue-up, wedges are driven into the tenons to lock everything tightly in place. This step not only strengthens the joint but also adds a handmade, traditional look to the bench.
Once the glue dries, the tenons are flush cut to the bench surface. Caleb then goes back with a sander and smoothing plane to refine the final surfaces and blend all the joints.
Applying the Finish
To bring out the wood’s natural character and add protection, Caleb applies three coats of General Finishes Arm-R-Seal. He sands lightly between coats to achieve a smooth, even finish.
The result is a bench with a warm, rich appearance that highlights both the wood grain and the craftsmanship of the joinery. The finish also adds durability, making the piece suitable for everyday use.
A Project That Builds Skills and Confidence
This bench is more than just a seating solution—it’s a deep dive into traditional woodworking techniques. Caleb’s step-by-step approach makes the process approachable, even for woodworkers just beginning to explore advanced joinery.
With a focus on precision, planning, and patience, this project demonstrates how careful craftsmanship leads to results that are both functional and beautiful.
Please support Caleb by visiting his website: https://www.ycmt2.com/.