When I received the wood for this project several weeks ago, I was in awe of the color and quality and the SMELL.
The top especially just floored me. It was almost three inches thick and about forty inches by thirteen inches. The trip from the northern part of the country (I literally chose my boards from photos online) was a little bit rough on the edges but I was determined to retain the overall dimension of the slab for the top. The bench was very angular so instead of rounding-over the sides of the top I decided on a handsome chamfer instead (45 degree cutoff—just deep enough to get rid of the dents from the shipping process and ease the edges).
The thickness of the top was exciting but it also presented some design challenges. Even though a relatively-square top looked fine to me in my SketchUp model, when I had completed the base and placed the slab on top for the first time I thought it looked unbalanced. The top had a “weight" that distracted from the delicateness of the base. I texted Pam a few photos and asked her to help me design a top that worked with that base. The next day, I added a small bevel to the ends of the top and with Pam’s help the following weekend, we nailed it. Pam literally just sketched a line onto the top at an angle she thought looked right, then we measured the angle, set the track saw and it was perfect.
The angle flows perfectly from the taper of the three matching legs up to the top. Since my track saw has a maximum cutting depth that is just-shy of the thickness of the top (and even shorter at an angle), I had to finish the cuts with a flush-trim saw. It’s a kind of hand-saw with no “set” to the teeth. In other words, the teeth do not cut sideways, just flat.
I had decided fairly early-on that I wanted to make Luke’s ashes a hidden feature of the bench. When I thought of hidden furniture features, I was thinking initially of a drawer. In my mind one of the end-grain sides would be carefully cut into mitered components so that it would slide out and reveal a hidden compartment. The problem with this concept however is that even slight amounts of wood movement could cause the drawer to get stuck and, with the amount of material I would need to remove, I could be seriously messing with the stability of the wood. I found a blog post about a woodworker who had created a cavity inside of his shop workbench for a paper-copy of the plans he had put together for the workbench. He had it in his mind that a future owner would find these plans and…well, I’m not sure what he was thinking. His decision struck me as a bit odd, but it seemed like a perfect solution for my situation. With almost three inches of depth I could easily route-out a place with enough room to carry Luke’s ashes. That’s what I ultimately did.
Just like when I used my table saw, I was using a less-than-ideal tool to do something important. With the help of a well-positioned template (and at the expense of a couple if bits), I was able to make a cavity for Luke’s ashes that was just the right size.
The finish I used is an oil-wax mixture made by the same company that designed many of my tools. As a Mac-user, I know how nice it is to work within a cohesive ecosystem. The same applies here. The finish method I used involves wiping on a coat of the oil-wax mixture with a special sponge, waiting fifteen minutes, “sanding” the wood with a kind of green scotch-bright sanding disk to really rub it in, waiting 6-8 hours, sanding lightly to 320 grit (extremely fine), putting on a second coat with the sponge, waiting another 15 minutes and then lastly using a white polish-pad on the sander to finish it up. This sounds like a lot of steps but the ability to apply a flawless finish within 24 hours is a pretty amazing feat. The bench is intoxicatingly smooth. I love it.
While I was planning, I had submitted a question to a woodworking podcast related to attaching the base to the top and the guys on the podcast answered my question during one of their shows (http://www.woodtalkshow.com/episodes/wt222-freaky-teaky-crud/). Because of how I designed the base I was able to use a different method than I had asked about, but I was honored that they took the time to respond.
When the time came I centered the base over the upside-down top and counter-sunk six screws into the top. I over-sized the holes for the screws so as to allow for seasonal wood movement. Once the screws were in place I plugged the holes with tapered plugs that I was able to cut from the walnut scrap with a matched plug-cutting bit. Once glued, I flush-cut the plugs and used a cabinet-scraper to make things smooth again. The contrast looks great.
I waited for Pam to get home before I placed Luke’s ashes in their place. She was extremely involved in making this bench a reality and she needed to be involved during this part. Once inside, we took turns fastening the cover to the bench.
Once everything was in place we needed to put the bench in it’s new home. That was always going to be in the place of Luke’s crib. This meant packing the crib away for the first time since he died. I don’t need to explain that it was difficult for both of us. Doing it now though, we were able to replace it with something very meaningful and (I hope) honoring of Luke’s life. We'll keep the blanket that Pam made for Luke, his smaller acorn urn and the Orange Bird pillow I got Luke for Christmas nearby.
I confess that the legs have rocked on every surface it has stood since I put it together. This was one of the side-effects of my mal-aligned table saw, I think. Still, when the bench was put in the place of Luke’s crib, the legs stood perfectly flat on the ground. It was like I was hearing “you built it just right”. What a gift.






























