|Project by Karson||posted 07-26-2008 03:03 AM||15543 views||10 times favorited||73 comments|
I made this bench about 2 years ago and then it was covered up by “Stuff”. I had invited Lee Jesberger to come to the Mason Dixon Woodworkers Club Picnic on July 20, 2008 and so I decided to clean up the shop a little. (I still left enough “Stuff” around to be able to find it later.)
The first item that I uncovered was the bench. Therefore this post. And of course since it was made from Recycled materials I needed it to be entered in the Summer LumberJocks contest.
The legs, stretchers, aprons were all made from some Maple that I picked up in St Louis over 30 years ago. That in it’s self should qualify as recycled. But I ran across this maple. (Newspaper or driving by I don’t know).
I found the wood in a salvage yard. The company was a demolition company and they got the contract to tear down the remnants of a warehouse, factory that had caught fire. The brick building was being knocked down with a crane and the materials being removed with a bulldozer.
Down in the basement they discovered around 2 Million Bd Ft of Hard Rock Maple. Most of the wood was 10 quarter thick, random widths and random length. So I was loading about 27 CU FT of wood in my van every so often. That’s about 3’ X 3’ X 3’. I was paying 5 cents a bd ft for the wood. That was about 324 Bd ft in a load and it cost me about $16.00.
The wood had brick and stone and moter pieces embedded in the wood. I used a body grinder that I put a wire wheel the go over the surface of the wood before running it through my planer.
I made children’s toys with the wood, that I sold at Craft Fairs.
After many trips of doing this I finally asked to site manager what he would charge if I took a whole pile. The pile i selected had about 20,000 BD FT. He said 2 cents a bd ft. So I bought it.
I’ve got about 100 BD Ft left after moving twice and all of the toys.
No one knows the true story, but it was thought that the factory made either 1) Bowling Pins or 2) Ladies High Heels for a shoe Mfg. I just know that there was a lot of wood going to waste sitting uncovered in an outdoors yard.
The entire frame, legs were made from that maple. The legs are 2 1/4” thick by 4” wide. The Apron is 2 1/4 X 7” wide. The base is 2 X 4”. The legs are mortise and Tenoned into the base and the apron is M&T into the legs.
The stretcher is 2 X 7”. There is one at the front and the back. They are bolted to the legs.
The top is another story.
It is a piece of a bowling alley. It is the maple section that is used as your entry into the bowling lane. I originally picked up three pieces 4+ ft wide and 10+ ft long. They were tearing out a bowling alley on my way home from work and I stopped by and picked up a few pieces. The wood was gotten for making my kitchen cabinet counter top for the kitchen i was making for my wife in NJ.
Bowling Alleys are not glued. They are tongue and grooved and then have hardened nails shot through the groove.
I used a nail cutting blade in a skill saw and would cut about 1” for the first cut. Then I’d drop it about 1/2” and cut through the nails and then lower it to the full depth of the saw and do the last cut as deep as it would go. I would use a ZipSaw to separate the two pieces. I would always cut through the middle of one of the boards and then I would peal that board off, Use a muffler cutting blade on an air grinder and cut the pieces of nails off to the surface of the groove. I now had a nice smooth surface to put on additional strips of wood to give me the final width.
On the making of this top I wanted to put bench dog holes and I knew that I’d hit nails some where down the run of holes so additional strips of wood were glued on so that I’d would not hit any nails.
The bench is 97” long, 30” wide and 37” high. The top is 2 1/4” thick maple, 1 1/8” wide strips. Not glued, just nailed together.
The vise on the left is an clone of an Emmert Patternmakers Vise, and on the right a ShopFox quick release 7” vise. The breadboards are Macacubba from Central America, with a tenon on the bench top and the mortise in the Breadboard. Pegs are driven through the breadboard and through the tenon to hold it in place. The top has about 44 BD FT of wood and just sits on square pegs on top of the legs into square holes on one side of the top and a rectangle mortise on the other side. This allows the top to move. There is no finish on the top.
The drawer cabinet underneath is just a box that was made to sit on the stretchers. It is not attached. It is not recycled wood.
The wood is 3/4” birch Plywood, with 6 drawers of varying depths.
The drawers are veneered with Waterfall Bubinga Veneer and the bead edging on the drawers is Grandillo. The top and bottom drawers on the right are mirror image matched on the veneer and the left drawers are mirror imaged with the right drawers. There is a space above the cabinet that allows the bench dogs to go through the wood surface. I also store my 16” saw blades for my table saw on the top and my cast iron honing plates that I use with diamond paste for sharpening.
-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware email@example.com †