In this project, Anthony and Bob Barker from Wood Pack DIY guide us through the creation of a stylish and functional storage bench. Designed to enhance the front entryway, this bench serves as a perfect spot for sitting down and storing items, making it an excellent addition to any home. Using solid walnut, the duo shares their process, challenges, and solutions to create a beautiful piece of furniture.
Materials and Tools Needed
- Solid walnut lumber
- Veneered plywood (optional)
- Wood glue
- Pocket hole screws
- Clamps
- Crosscut sled
- Miter saw
- Router
- Chisels
- Dado stack (optional)
- Sandpaper (various grits)
- Polyurethane finish
- Upholstery fabric and padding (for the top)
- Rubber feet (optional)
- Drawer slides (undermount)
- Finger pulls for drawers
- Jigsaw
- Drill
Step 1: Plan and Cut the Wood
The project begins with the need for a storage bench by the front door for convenience. After discussing the design with his wife, Anthony decides to build the bench out of walnut. They head to the lumber yard to select the wood.
After obtaining the walnut, they rip it down to the necessary sizes for the frame and panels. Initially, Anthony planned to use veneered plywood for the panels, but later opts for solid walnut instead.
Step 2: Create Rabbit Joints
Using a miter saw and stop block, they make repeatable cuts for the joints. Anthony emphasizes the importance of accurate cuts to ensure tight joints. They then proceed to create rabbit joints to inset the panels.
Step 3: Assemble the Panels
With the panels cut, Anthony begins to glue them into the rabbit joints. Due to a shortage of clamps, he has to work on one panel at a time, waiting for it to dry before moving on to the next.
Step 4: Construct the Legs
Next, they cut the legs for the bench, again using rabbit joints. Anthony discusses his choice of saw blade, opting for one that would provide the smoothest cuts.
Step 5: Join the Legs and Frame
Once the legs are prepared, they are glued and clamped to the frame. Anthony checks for squareness throughout the assembly process to ensure everything fits perfectly.
Step 6: Build the Drawer Structure
With the frame and legs assembled, Anthony moves on to constructing the internal structure for the drawers. He uses pocket hole screws for secure assembly.
Step 7: Create the Drawers
Now it’s time to build the drawers. Anthony cuts plywood for the drawer boxes and uses a dado stack to create grooves for the bottom panels.
Step 8: Attach Drawer Slides
With the drawers completed, he installs undermount drawer slides, ensuring they fit perfectly within the constructed frame.
Step 9: Prepare the Top
For the bench top, Anthony marks and cuts the wood before using a flush trim bit on the router for a perfect finish. He had originally planned to upholster the top himself but decided to have it done professionally.
Step 10: Final Assembly and Finishing Touches
After everything is assembled, the final step is to apply a polyurethane finish to protect the wood and enhance its natural beauty. Anthony carefully applies the finish, ensuring an even coat.
Finally, the upholstered top is secured, and the project is complete. The bench is now ready to be enjoyed, providing a perfect spot for sitting and storage.
