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Zebrano Bench

Wooden Shoe Bench
12 Week Project

Project Objective:
Creating a functional and beautiful piece of furniture built entirely from wood. No screws or fasteners, wooden joinery only.

Research

Anthropometry Study of a Bench

Survey on User Preferences

Manufacturing Process

Tools for Construction

Materials - Types of Hardwoods

Style Characteristics

Sketches

The final model is based on the final sketch, #31

Models, 1/4 scale

The final model is based on the final Moc Model #7

Detail Control Drawings

Full-Scale Moc Model

A rough model was constructed entirely out of pine and plywood in one week. The strength of the bentwood seat-pan and its supports was tested.

The types of joinery used in this model proved to be too weak and incorrectly placed. Much was learned, and corrections were made for the final model.

Construction

A blend of two striking hardwoods for the final: Walnut and Zebrawood.

Constructed an MDF mold.

Bendable plywood remained clamped as shown for 24 hours on the wood.

A walnut veneer was clamped to both sides after.

The veneer and support frames were sanded down with a handheld sander.

Aligning the front and back frames of the bench.

Test-fit of frames, seat pan, and side panels. Standing and leveling test.

Coated joinery in wood glue.

Dried 12 hours overnight.

To finish the shoe bench, the entire bench was sanded with 800 grit. A high-gloss oil-based polyurethane was used. I applied it using a combination of a microfiber cloth, a paintbrush, and a roller brush. Six coats of polyurethane were applied in total, with drying times of four to eight hours in between.

Final Model

The final design, Zebrano, is built of zebrawood and walnut, with the seat being made of bendable plywood with a walnut veneer over it. Zebrano is finished with a high-gloss, oil-based polyurethane.

Takeaways:
This bench came with many challenges, but it was a rewarding and educational project.

The ergonomics of the bench work well together, creating a comfortable height for putting on and removing shoes. The side table also doubles as an armrest, acting as both an armrest and a support surface to push off from when standing. The zebrawood and walnut create a strong visual together. Both are such rich materials, and the oil-based finish brought out the warmth of both woods

After reflecting on the final design, I have some aspects I would change. The first is the finish. I wish I’d applied a satin polyurethane in place of a high gloss. I feel the gloss finish gives it a plastic-like appearance, taking away from the natural wood. I would also change the shape of the backrest and bottom frame pieces to better complement the shape of the seat pan, achieving a more fluid look. I would also alter the front frame that connects to the seat pan. Currently, the frame is divided into three parts, connected through lap joinery. I would have liked to showcase the lap joinery better, as it ended up being hidden in the final assembly. Finally, I would have altered the design to support the bench seat differently, as two pieces of the frame have a horizontal grain, and one piece in the middle has a vertical grain. This was done intentionally to support the weight of the seat pan, but the visual disruption is not favorable. If I were to change this, I would have overlapped the vertical grain with a thin veneer of horizontal grain to keep the visual flow uninterrupted.

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Hi, I’m Zoe Malani!

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