I built a large dining table many years ago, but we moved and the new space was too small for it. This year, my son and his family were coming for Thanksgiving and we needed more seating. So we moved the table in and decided we could make it fit if I built a sitting bench to go against the wall that would seat two people when the table was pulled out.
I found a suitable slab of hickory with bark on that I could use for the seat and legs. It was rough sawn so I took it to a friend's commercial shop to get it sanded down. Unfortunately, the sander found a nail that ruined one of the two belts and we had to take it to his three belt sander to finish. (this is the first sander) I started by marking out the mortise locations, routing out the center and finishing them with chisels.
I cut the tenons then went on to the tedious work of trimming them to fit.
I had to remove all of the bark since it was starting to fall off. I started pounding the legs into the mortises (no glue), and it broke my mallet. So, I went with metal hammers with a tubafour to take the damage. Got within a 1/4" of seating them and the tubafour was done. Grabbed a 4 lb sledge and got them seated. Trimmed off the tenon protrusions, sanded it and finished it with BLO/MS gradually increasing the BLO concentration. Lots of work but the wife was happy. Thanks for looking.
"Duck and Bob would be out doin some farming with funny hats on." chrisstef
Splint, that belt was worn anyway and they had a stack of replacements. My wife is using the bench all the time now. And yes, I re-glued the mallet and put brass pins in. Ryan, it sits flat with no wobble or racking. The slab is 1 1/2" thick and as hard as it was to seat the legs, I don't expect any issues in the future.
"Duck and Bob would be out doin some farming with funny hats on." chrisstef