Good friends, Joyce and Alan, needed a bench so I thought I would capture the steps
Day 1
Start with a slab of elm which has been stored and dried, and sketch out the cuts to be made to create the parts we need.
![](https://shenwall.com/wp-content/uploads/2021/03/slab-1024x887.jpg)
![](https://shenwall.com/wp-content/uploads/2023/09/IMG_0056-969x1024.jpg)
Cut out legs
![](https://shenwall.com/wp-content/uploads/2021/03/Cut-outs-1024x991.jpg)
![](https://shenwall.com/wp-content/uploads/2021/03/Legs-669x1024.jpg)
Create a rough cut kit and start sanding with a decent belt sander and good dust extraction…
![](https://shenwall.com/wp-content/uploads/2021/03/kit-962x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/03/sand-slab-1024x573.jpg)
Sanding gets rid of cut lines from the band saw. IF there is a split in the end grain then simply add a little bow tie to stop it from spreading
![](https://shenwall.com/wp-content/uploads/2021/03/Sand-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/03/bow-tie-768x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/03/kit-rough-sanded-1024x521.jpg)
Day 2
Start cutting joints to join legs to seat
![](https://shenwall.com/wp-content/uploads/2021/04/bench-1-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/04/bench-2-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/04/bench-3-1024x768.jpg)
Now add pieces for the arms and start cuts to join arms to legs
![](https://shenwall.com/wp-content/uploads/2021/04/bench-4-768x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/04/bench-5-768x1024.jpg)
Day 3
Create mortise and tenon joints for arms and chair back plate
![](https://shenwall.com/wp-content/uploads/2021/04/bench-7-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/04/bench-8-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/04/bench-6-768x1024.jpg)
Now fit all together to give first rough assembly before we start finishing
![](https://shenwall.com/wp-content/uploads/2021/04/bench-11-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/04/bench-9-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/04/bench-13-768x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/04/bench-10-1024x768.jpg)
Day 4
Sanding and more sanding with 80 then 120 grit… then stain
![](https://shenwall.com/wp-content/uploads/2021/05/bench-sand-120-1024x768.jpeg)
![](https://shenwall.com/wp-content/uploads/2021/05/bench-stain-1024x768.jpeg)
![](https://shenwall.com/wp-content/uploads/2021/05/bench-kit-1024x768.jpeg)
Day 5
Coat of epoxy resin
![](https://shenwall.com/wp-content/uploads/2021/05/Bench-17-768x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/05/Bench-16-768x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/05/Bench-14-768x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/05/Bench-15-768x1024.jpg)
Day 5B
Now scrape off the epoxy resin because I didn’t mix it well enough and it hasn’t fully set leaving it tacky. Then sand everything back and reapply the resin
![](https://shenwall.com/wp-content/uploads/2021/05/bench-18-rotated.jpg)
![](https://shenwall.com/wp-content/uploads/2021/05/bench19.jpg)
Day 6
Now with one good coat of epoxy and one coat of yacht varnish, we now do final assembly i.e. Glue Clamp and Screw
![](https://shenwall.com/wp-content/uploads/2021/06/bench-21-768x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/06/bench-20-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/06/bench-22-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/06/bench-23-1024x768.jpg)
All that’s left to do now is another couple of coats of yacht varnish with light sanding between coats
![](https://shenwall.com/wp-content/uploads/2021/06/bench-27-768x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/06/bench-28-768x1024.jpg)
![](https://shenwall.com/wp-content/uploads/2021/06/bench-25-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/06/bench-24-1024x768.jpg)
![](https://shenwall.com/wp-content/uploads/2021/06/bench-26-1024x768.jpg)
Day 7
Deliver and install
![](https://shenwall.com/wp-content/uploads/2021/07/bench-30-1024x768.jpg)