| Project by Karson | posted 343 days ago | 3668 views | 5 times favorited | 64 comments | ![]() |
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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.


-- Karson Southern Delaware karson_morrison@bigfoot.com †































64 comments so far
PurpLev
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1777 posts in 400 days
posted 343 days ago
That is one Prutty Top!!!
-- When in doubt - There is no doubt - Go the safer route.
tenontim
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1230 posts in 496 days
posted 343 days ago
Nice bench, Karson. Where’s the ball return?
-- Tim -- http://tmuli.com
Richard Williams
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128 posts in 544 days
posted 343 days ago
Wow you are good. Too bad we are not next door neighbors I would become your apprentice. I can do simple things but my expertise is not in wood. In fact as I am fast approaching 65 in about a little more than a week on the 6th, I still don’t know what I am really good at. :) I’ve been very busy on a project working in collaboration with our local University here in Las Vegas. I know I have not been around much but this project is a humanitarian one that grabbed my interest right away. Should take a few more months. Take care and how have you been feeling? God Bless All.
-- Rich, Nevada,
ChicoWoodnut
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884 posts in 567 days
posted 343 days ago
So what happened to the othe 1.9 million bd ft of maple?
-- Scott - Chico California http://chicowoodnut.home.comcast.net
Bradford
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694 posts in 574 days
posted 343 days ago
I vote for this bench to be best use of recycled wood as the cornerstone tool for all other projects starting point. Wow, what a bench. This is a tool after my own wooden heart. Thanks for this post. I just got a woody.
-- so much wood, so little time. Bradford.
Karson
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21155 posts in 1152 days
posted 343 days ago
Richard. I’m feeling great. Just getting started on my second set of kitchen cabinets for my wife. (Blogs to follow).
Tim I knew I forgot something. Dang now I’ll have to tear it apart and add the enhancement. You can bet that won’t happen again.
Lev Thanks for the comment.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
Karson
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21155 posts in 1152 days
posted 343 days ago
Scott I wish I knew what happened to the other wood. Of course this lot also had 16 X 16” beams that would today be great to cut up with a woodmizer and give some great wood.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
depictureboy
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202 posts in 394 days
posted 343 days ago
Karson that is absolutely beautiful…I can’t wait till the day when I can build my bench…thanks for sharing.
-- If you can't build it, code it. If you can't code it, build it. But always ALWAYS take a picture.
sIKE
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968 posts in 505 days
posted 343 days ago
I love the waterfall Bubinga! The bench looks great!
-- //FC - Round Rock, TX - "Experience is what you get just after you need it"
daveintexas
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292 posts in 627 days
posted 343 days ago
That is a wonderful looking workbench, and well thought out.
I should have known there would be veneer involved if Lee Jesberger was around. lol
thanks for sharing
-- MISSION FURNITURE-My mission is to build furniture
gizmodyne
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1633 posts in 841 days
posted 343 days ago
Awesome bench. Way to recycle. Love the veneer. We might need a new shop inspection if you are going to start cleaning.
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne
trifern
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7776 posts in 518 days
posted 343 days ago
I would struggle getting any work done on this bench. I would simply stare and admire those drawer fronts. Thank you for sharing.
-- My favorite piece is my last one, my best piece is my next one.
Napaman
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2820 posts in 828 days
posted 343 days ago
amazing…
-- Matt, Napa, CA...sanity...has arrived...JUNE-JULY-AUGUST...
GaryK
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9429 posts in 740 days
posted 343 days ago
Very cool bench. I used an old bowling alley for mine also, except I took all the nails out re-surfaced all the wood and glued it back together.
Looks like we both have a lot of the same stuff. Heavy Duty aluminum foil, boxes of nitril gloves and a box of reguar latex gloves, and even a set of red earmuffs!
-- Gary, East TX -- The longest journey begins with a single step.
CharlieM1958
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6680 posts in 970 days
posted 343 days ago
That wood was quite a score, Karson! And the benchnis beautiful! I love that bubinga veneer. I have a bit myself just waiting for the right project(s).
-- Charlie M. "Woodworking - patience = firewood"
ChicoWoodnut
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884 posts in 567 days
posted 343 days ago
Ahhh I see.
Nice that you could salvage a pile and turn it into somthing nice.
-- Scott - Chico California http://chicowoodnut.home.comcast.net
Texasgaloot
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467 posts in 452 days
posted 343 days ago
Looks like you had quite a strike. Glad you could frame it out this way, with wood to spare, without splitting hairs. Thanks for the bowl down memory lane.
-- There's no tool like an old tool...
Dadoo
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1674 posts in 742 days
posted 343 days ago
Real nice project Karson!
-- Bob Vila would be so proud of you!
DAN
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5391 posts in 734 days
posted 343 days ago
looks like that table will last a couple hundred years. truely fine
-- work from your heart and your spirit will live forever
Woodhacker
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1151 posts in 475 days
posted 343 days ago
Great looking bench Karson. I love the water fall bubinga. I recently bougtht some and am waiting for just the right inspiration and project.
Thanks for showing this.
-- Martin, Kansas
Douglas Bordner
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3316 posts in 815 days
posted 343 days ago
If there is wood to be salvaged you can bet Karson will be on it like a duck on a junebug. That is one splendid bench. Good luck in the contest.
“The wood was gotten for making my kitchen cabinet counter top for the kitchen i was making for my wife in NJ.”
Does your wife in Delaware know about your wife in New Jersey? =^}
-- "Bordnerizing" perfectly good lumber for over a decade.
rikkor
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11345 posts in 626 days
posted 343 days ago
That bench would have to retail for about $4500.00. Gorgeous!
Karson
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21155 posts in 1152 days
posted 343 days ago
No Douglas and I’d appreciate it you don’t tell her.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
SteveKorz
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2007 posts in 465 days
posted 343 days ago
Karson, that is a very nice bench! I really like the Bubinga
-- As iron sharpens iron, so one man sharpens another. (Proverbs 27:17) †
Lee A. Jesberger
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3495 posts in 731 days
posted 343 days ago
What Karson failed to mention is the handles are diamonds. Anything less would be uncivilized. lol
If you guys could see the stash of wood Karson has, it would bring tears to your eyes. I cried the whole way home.
And the bench looks even better in real life.
Great job Karson.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Douglas Bordner
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3316 posts in 815 days
posted 343 days ago
Mum’s the word, Pal.
-- "Bordnerizing" perfectly good lumber for over a decade.
Grumpy
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12048 posts in 602 days
posted 343 days ago
Top story Karson. I like the bench.
-- Grumpy - "Always look on the bright side of life"- Monty Python
MsDebbieP
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13439 posts in 912 days
posted 343 days ago
the story is as amazing as the bench itself!
well done
-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)
TheGravedigger
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209 posts in 775 days
posted 343 days ago
Wonderful stuff, Karson. That’s going to be tough to top as a recycle project. Plus, there’s nothing like the satisfaction of making toys for kids.
-- Robert from Raymond, MS. "We are what we repeatedly do. Excellence is therefore not a practice, but a habit." - Aristotle
cobbler
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211 posts in 542 days
posted 343 days ago
Great bench. Great story also.
This will surely be #1 or #2.
Thanks for sharing.
-- ''Carry on my wayward son''
Karson
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21155 posts in 1152 days
posted 343 days ago
I appreciate the comments guys. And Lee I offered you some wood and you didn’t take it. Well maybe that was under my breath that I offered it.
Lee did point out the Diamond drawer pulls. I didn’t mention them because I didn’t want anyone showing up to rip them off.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
Gary
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377 posts in 1075 days
posted 343 days ago
Karson,
That’s a great story, a great bench, and an even greater use of recycled material.
Fantastic!
-- Gary, Florida
teenagewoodworker
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2374 posts in 519 days
posted 343 days ago
real nice bench you’ve got there! great way to recycle all that wood too!
SPalm
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833 posts in 633 days
posted 343 days ago
I’ve said it before, and I’ll say it again:
When I grow up I want to be just like Karson.
Nice job, and good finds,
Steve
-- Stevethepeeve -- I'm no rocket surgeon
Blake
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2560 posts in 626 days
posted 343 days ago
Geez Karson, This is gorgeous! Great project.
-- Check out my new website! http://www.blakeweberwoodworking.com
jeanmarc
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1750 posts in 468 days
posted 342 days ago
Nice bench, Karson.
-- jeanmarc manosque france
thetimberkid
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1945 posts in 454 days
posted 342 days ago
Wow, great job!
Thanks for the post
Callum
-- For wood working podcasts with a twist check out http://thetimberkid.com/
relic
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338 posts in 688 days
posted 342 days ago
It has to say something when the wood out shines the diamonds. That bench is really nice.
-- Andy Stark
Karson
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21155 posts in 1152 days
posted 342 days ago
Again I appreciate the fine and caring comments.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
jerryw
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74 posts in 667 days
posted 342 days ago
your wookbench is worth a furtune. i bought fas hard maple yesterday for $2.90 bf.
-- jerryw-wva.
FRITZ
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78 posts in 350 days
posted 342 days ago
Very nice bench,bubinga is my favorite
Thanks Fritz
Bob A in NJ
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400 posts in 750 days
posted 342 days ago
Karson
Wow, very nice and very cool looking bench, I love it.
Bob
-- Bob A in NJ
Karson
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21155 posts in 1152 days
posted 342 days ago
Thanks Bob.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
miles125
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1314 posts in 757 days
posted 342 days ago
Great bench Karson!
-- miles125, Alabama.."Architecture is frozen music""
Dick, & Barb Cain
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6381 posts in 1051 days
posted 342 days ago
No one can beat this one!
You must have the best of all noses for sniffing out great lumber deals.
Good Luck Karson!
-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
daltxguy
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446 posts in 665 days
posted 341 days ago
I’m going to drive by our 1 bowling alley every day from now on – you never know cause I doubt anyone here has 2m bd ft of maple hidden away. Great story, great use of some fine recycled wood
-- Steve, New Zealand, www.steveracz.com
Karson
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21155 posts in 1152 days
posted 340 days ago
Steve:
I got a phone call from a guy at the office one day saying that a bowling alley about 1 mile away was taking out one line because it was a bad lane. He told me so I could go and get it. At the time I had thought I had enough bowling alleys. So I didn’t do it.
But here in Delaware A bowling Alley went out of business and so I kept my eyes on what was going to be done to the building. I then saw some construction activity. I went by and they stated that the cost to take out the alleys was higher than building a new floor over them. So that was what they did.
I failed to ask them if I could cut out a couple of sections for no charge.
Maybe I’ll be smarter next time.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
YorkshireStewart
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753 posts in 652 days
posted 340 days ago
A great example of recycling Karson. I just hope you can keep all that ‘stuff’ off the top now!:-)
-- Res severa verum gaudium - True pleasure is a serious business. http://www.folksy.com/shops/TreeGems
Karson
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21155 posts in 1152 days
posted 340 days ago
Stewart.
It’s full of patterns for the new cabinets and parts lists. But I guess that’s good. At least I’m using it and not storing stuff.
This is a before picture.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
woodworm
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5811 posts in 342 days
posted 334 days ago
Thanks for your views on the TS 2500ci.
Take care of your beautiful workbench. The drawers shd be in my bedroom if I ever can afford to build.
-- Regards, Woodworm - KL, MY.
DAN
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5391 posts in 734 days
posted 334 days ago
another look and I’m still impressed. good one. oil that baby up !
-- work from your heart and your spirit will live forever
Karson
home | projects | blog
21155 posts in 1152 days
posted 334 days ago
Thanks Dan and Woodworm.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
Michael Brailsford
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210 posts in 345 days
posted 334 days ago
It just goes to show if you keep your eyes open you can find great wood cheap. Beautiful work
-- Michael A. Brailsford
Grumpy
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12048 posts in 602 days
posted 333 days ago
Good luck in the contest Karson.
-- Grumpy - "Always look on the bright side of life"- Monty Python
Napaman
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2820 posts in 828 days
posted 333 days ago
diamonds??? wow…i am in the wrong line of work…
GREAT BENCH>>..,good luck in the contest…
-- Matt, Napa, CA...sanity...has arrived...JUNE-JULY-AUGUST...
RobS
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1191 posts in 1058 days
posted 332 days ago
So… now all your projects are “right up your alley”?? or is that right up on your alley…?
A perfect score. great work.
-- Rob (A) Waxahachie,TX
jinxedjohn
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3 posts in 383 days
posted 329 days ago
Now, the storing picture is what it would look like around my house if my wife had anything to do with it!!! That woman makes me look really organized!
Congratulations on your beautiful project! It is simply amazing and some very beautiful wood too!
-- John
john
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973 posts in 1133 days
posted 329 days ago
Very nice job karson and congrats to you on your entry .It couldn,t happen to a nicer guy .
-- John in Belgrave http://www.extremebirdhouse.com ....http://community.webshots.com/user/cranbrook2
jeanmarc
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1750 posts in 468 days
posted 329 days ago
congratulations for the second places very beautiful work
-- jeanmarc manosque france
vmullins
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4 posts in 822 days
posted 327 days ago
Karson,
I have a bouwling alley in my town, Cleveland MS that is getting ready to close. Any tips on how to get the floor up. It jst so happens that I have just finished my new shop and I have been looking around for just the right bench to build. I think your beautiful design would suit my needs just fine
-- Virgil Mullins
Devin St. Clair
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10 posts in 248 days
posted 211 days ago
Nice work bench! I like the contrasting woods and stains. I am just getting started and I have yet to make my work bench, so I’m excited about trying all my ideas. Your bench reminded me I want a pocket under the bench top for quick storage. I may use from these old (sloppy made) cabinets and “work bench” in my 58 year old house (Our first house!). But I’m going to put all the wood through a friends plainer and jointer first to get good fits and surfaces.
-- Devin
Tony Friendly
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15 posts in 212 days
posted 199 days ago
Karson,
You do beautiful work and have a terrifc talent, but it appears your life is a mess. (LOL) If your life was organized, you would be famous.
-- Tony Friendly, FriendlyFixer
HIsurferMoe
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25 posts in 168 days
posted 165 days ago
thats not a workbench…thats an executive work bench…very beautiful….one mans trash is another mans treasure…good job
-- SurferMoefoe
grizzman
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93 posts in 55 days
posted 34 days ago
KARSON, I WAS JUST LOOKING AT YOUR PROJECTS AND JUST AMAZED AT THE STORY OF THE MAPLE, AND YOUR WORK BENCH IS JUST BEAUTIFUL, YOU CERTAINLY WOULD BE A GOOD TEACHER FOR ALL THE KNOWLAGE YOU HAVE AND THE PROJECTS YOU’VE DONE, IM SURE GLAD WE CAN SEE YOUR WORK AND HEAR YOUR STORYS HERE AT LJ…..YOUR AN INSPIRATION…THANKS…GRIZZMAN
-- The Grizzone