Building a Japanese Bench

In this episode, I build a custom Japanese bench made of walnut and accented with mahogany. I start the video by sketching the custom bench design and then creating the bench from start to finish, demonstrating hand-cut Japanese joinery.

This bench was custom-built for a Colorado Springs custom furniture client.

Summary

Woodworking Process and Precision Techniques

Brian discussed his woodworking process, focusing on the construction of a bench. He detailed how he used a router to create the bulk of the mortise and tenon joints and then hand-chiseled the remaining parts to match the tapering legs. He also mentioned using a biscuit joiner to align the pieces and a hand plane to shape the wedges. He emphasized the importance of precision and accuracy in his furniture making and the satisfaction he derived from the final product.

From SketchUp to Sawdust: Crafting a Trestle Bench

Visualizing the Design: 3D Models vs. Full-Scale Sketches

I start almost every project by creating 3D models in SketchUp. It’s a fantastic way to visualize dimensions, angles, and overall proportions before making the first cut. But there’s only so much a digital model can tell you. Sometimes, you need to see it full-scale to truly understand the design.

That’s why I often sketch out my projects at full size. For this trestle bench, drawing it out helped me refine the leg angles, the height of the middle trestle, and the overall balance. A rough sketch may not be as precise as a 3D model, but it gives a tangible sense of scale that’s invaluable before committing to wood.

Rough Cutting: Letting the Saw Do the Work

When it comes to rough cuts, my trusty reciprocating saw (or “ready worm saw,” as I like to call it) is a beast. It chews through rough-sawn material without hesitation—though it did hang up a little here. I keep an aggressive tooth on the blade to minimize issues, and it’s perfect for breaking down lumber that isn’t perfectly square.

Joinery: Biscuits Before Dominos

This project was built before I owned a Festool Domino, so I relied on a biscuit joiner for alignment. I’d almost forgotten about that tool! While not as precise as a Domino, biscuits are still a great way to keep parts from slipping when clamping glued pieces together.

Mortise & Tenon: Handwork Meets Machine Precision

For the through mortises, I hogged out most of the waste with a router, then cleaned up the edges with a chisel. Since the legs are tapered, the mortise needed a slight angle—something easier to fine-tune by hand.

I chopped from both sides to ensure any inconsistencies would be hidden inside the joint. As long as the outer shoulders were crisp and tight, the interior imperfections wouldn’t matter.

For the tenons between the bench legs, I used my table saw to establish clean shoulders and then chiseled out the waste. This ensured the visible surfaces would be flawless, even if the hidden parts weren’t perfect.

Wedging It All Together

The tenon on the trestle needed to slide smoothly through the mortise without excessive force, so I tapered the leading edge slightly. Then, I hand-planed a wedge (admittedly with a dull plane—I should’ve sharpened it first!) to lock everything in place.

Of course, nothing fits perfectly on the first try. There was some back-and-forth finessing, but the satisfying thud when it finally seated was worth the effort.

Gluing & Clamping: A Balancing Act

Getting even pressure while clamping this assembly was tricky. At one point, I had to balance a clamp precariously to avoid shifting the joint. A little sketchy? Maybe. But it worked.

The Final Touch: Contrasting Wedges

Before final assembly, I added mahogany wedges to the walnut tenons for a subtle visual contrast. That extra pop of color elevates the craftsmanship and makes the joinery stand out.

The Finished Bench

And there it is—the completed trestle bench! From digital sketches to hand-cut joinery, every step was a mix of precision and problem-solving.

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