cross-posted from: https://sh.itjust.works/post/22165919

This entry of mine will not match the customary craftsmanship found in this community, but seeing as this was formerly a pile of miscellaneous, warped scrap 2x4 segments recovered from old pallets, I think I’ve made a reasonable show of things.

This bench is for my homegym, designed to be stood upon, which is why there’s a rubber mat inlaid on the surface, a leftover of the gym floor. My design criteria called for even the edge of the top surface to support weight, so the main “box” of the bench uses 2x4 segments mitered (badly) together at 45 degrees, held together with wood glue.

I then routed the inner edge to support a 1/2" plywood sheet, which is screwed into the box. And then the rubber mat is glued down to the sheet, so there are no visible screws.

Finally, the legs are also 2x4 segments, cut so the bench sits 43 cm (~17 inch) from the floor; this is only coincidentally similar to the IPF weightlifting bench standards. I used screws instead of glue, just in case the legs needed to be shortened later.

All edges were rounded over with a 1/2" bit, as the bench is expected to be picked up and moved frequently. And everything stained in cherry and clear-coated.

Some of the annoyances from using scrap included:

• Stripping old paint off. Awful chemicals, awful scrubbing, awful disposal.
• Sanding away twists along the 2x4 segments
• Filling nail holes or arranging them so they don’t draw attention
• My lack of experience with clamping and gluing wood that’s not dimensionally consistent

If I were to do this again, I’d figure out a way to reduce the amount of routing needed for the inner edge, since I essentially removed 0.75 inch by 1.5 inch of material all around the edge. This took forever, and perhaps a CNC machine would have simplified things, in addition to squaring and planing the surfaces before mitering.