How to Make a Shoe Bench Without Nails and Glue?

This product is an outcome of the MYP IB Personal Project. My goal was to learn how to design and manufacture furniture that is aesthetically beautiful, solid and offers the user smart and practical features. I have a basic knowledge on the subject acquired during my participation in a carpentry workshop offered by the school. After having identified and organized my ideas in a mind map, I decided that my goal will be to learn how to draw furniture by hand and using a 3D design program like SketchUp, to apply a Japanese assembly technique and to integrate electricity into my furniture. I decided to measure my success by taking the opinion of my primary sources on the development of my design and manufacturing skills relating to my final product.

I am fascinated by the idea of being able to make my own furniture according to my needs and I wanted to link my project to the subjects that interest me, in particular physics and mathematics. Knowledge of the laws of physics helps to avoid machine hazards during manufacturing. On the other hand, geometry is used during the design and manufacture of furniture.

I have had previous exposure to carpentry and electrical integration. For example, while completing an earlier school assignement, I leaned about electrical circuits and was helped by adult to integrate a solar panel to light LEDs in a model for a sustainable house. Also, I participated in a carpentry activity at school. I learned the basics of woodworking. As the end product we made a picture frame and a wooden box, but that was not my original design. Later, I participated with a team of adults in a competition where we had to use reclaimed wood to make a self-watering pot and we won the first prize.

To achieve my learning objectives, I will make two pieces of furniture. A shoe bench that offers a comfortable solution for putting on and taking off shoes while seated and a place to store shoes when you get home right away. A garden side table offers a mobile solution to illuminate the garden and make electricity accessible wherever people go to sit. Both products solve problems I have at home. I created this instructable to explain how to make a shoe bench using a Japanese joinery technique.

The problem:

We have to take off our shoes as soon as we get into the house. The entrance would get messy and my mom would ask to go and organize my shoes. From here came the idea of the shoe bench, which is practical since it allows you to sit down to put on and take off your shoes while offering a place to organise shoes immediatly and without hassle.

Here is what I needed to build my shoe bench.

Software:

I used SketchUp 3D Design Software to create the design. SketchUp allowed me to adjust the measurements with precision and see if the different pieces would fit together correctly.

Tools Used:

I used machines and help of professional carpenters, in there workshop. I linked the list of machines and tools I used to images from the internet. This is to help you to quickly identify them, especially if you are a novice..

• Tape measure
• Bandsaw
• Miter saw
• Orbital sander
• L-square
• Claw hammer
• Nails' puller
• Wood chisel

Materials Used:

• (1) 122x244 18mm blockboard
• Nails
• Transparent white glue
• Wood putty

I have got my inspiration from Japanese door entrances called "genkan". I started to draw my designs by hand. Then I sent it designs to some professionals to give me a feedback. I had to improve the design several times till I reached this point. I had to work quickly, because I was already late. I fell sick and my plan got delayed.

One of my learning objectives was to learn a Japanese Wood Joinery Technique (Kumiki) that involves interlocking wooden pieces without the use of nails, screws, or glue.

Kumiki joinery relies on precise cuts and joints that fit together tightly to form a strong and stable structure. Any slight error in the measurements or angles can cause the entire structure to fail.

a- Drawing the design

I used SketchUp to model my design as follows:

1. Open SketchUp and create a new file. "File" in the top left corner, and then select "New" from the dropdown menu.
2. Choose the measurement units you want to use for your model. "Window" > "Model Info" > "Units".
3. Select the Rectangle tool from the toolbar on the left-hand side of the screen.
4. Click and drag to create a rectangle each the shoe bench top and sides. You can use the measurements box in the lower-right corner of the screen to input the dimensions of each piece separately.
5. Use the Push/Pull tool to extrude the different sides to the desired height. Click on the top surface and drag it upwards.
6. Draw a small rectangle or square on the surface where two pieces will intersect. Select the rectangle and the surface of the piece it will intersect with, and then select "Intersect Faces" from the "Edit" dropdown menu. Use the Eraser tool to remove any unnecessary lines or surfaces. (I did it in a different way, I cut a rectangle from a side and added it to the pieces that will interesect with that side.
7. Repeat the previous step to create all the kumiki joints.
8. Save your model by selecting "File" > "Save".

B- Testing and visualising the design to ensure that the final product will fit together correctly

1. Move the pieces into position relative to each other. You can use the Move tool to move the pieces around until they are positioned correctly.
2. Use the Rotate tool to adjust the angles of the pieces if needed. Select the piece you want to rotate, click on the Rotate tool, click on the point where you want to rotate around, and then click again on the endpoint where you want to rotate to.
3. Use the Scale tool to adjust the size of the pieces if needed. Select the piece you want to scale, click on the Scale tool, click on one of the handles to resize it, and then click again to confirm.
4. Use the Intersect Faces tool to create the connections between the pieces. This tool allows you to create the shape of the products when they are assembled. To do this, select the pieces you want to intersect, right-click and select "Intersect Faces" from the dropdown menu, and then select "With Model" from the second dropdown menu.
5. Use the Eraser tool to remove any unnecessary lines or surfaces created by the Intersect Faces tool.
6. Test the design by moving and rotating the assembled pieces to see if they fit together correctly. If any adjustments are needed.
7. Save your model by selecting "File" > "Save".

C- Creating a cut list for the carpenters

I created a list of the pieces needed for the shoe bench with the sizes they needed to be cut to, to be able to communicate clearly and easily with the carpenter and explain the design.

I attached SketchUp design file. Feel free to modify and use it.

In the beginning, I discussed my project with the carpenters. I explained my idea. One of them pointed out that the structural integrity of the bench would be abysmal if I used Japanese joinery, but i didn't heed their warning and continued with my work, not realizing I would need to reinforce the bench with more wood later on.

I started by cutting a 244x122cm^2 in two. Then measured the size of my design. I kept cutting the plank into smaller and smaller pieces to the size of the design:

a) 4 40x40cm^2 planks

b) 2 80x40cm^2 planks

c) 2 80x20cm^2 planks

First, using a L-square ruler and a pencil, I drew the mortises (hole or recess carved into wood), and the tenons (the corresponding piece which fits into the mortise) on the different planks that will form the sides and sections of the bench. Then, a carpenter cut them using the band saw. Although, they allowed me to use the band saw to cut the planks, they judged cutting the mortises and tenons require more experience and higher precaution.

I assembeled the bench to test it, it was shaky. It would bend and skew over to the sides. The low quality of the wood I used for this project was the reason behind the instability of the bench. As I used a blockbord made with recycled planks that was not well bonded and had missing planks in between. I had to glue the pieces and add nails. I was also recommended to add a back to my bench, which I did.

The carpenter sanded the wood to make it smoother, and we added a wood filler to hide the small small holes and imperfections. The bench looks more aesthetically pleasing.

I created a survey and sent it to my colleagues and teachers at school. I also posted it on a few social media platforms. I did not set any age limits.

I wanted to know the opinions of both young people and adults. 113 people started filling out the survey, and 82 completed it up to the last question. I received responses from people who live in 15 countries in 27 different cities around the world. More women (68%) than men (32%) completed my survey. The age of the people who completed my survey ranged from 11 to 69 years old. The majority are middle school students between 11 and 17 years old. Therefore, the result mainly reflects the opinions of young people.

98% respondents found the shoe bench practical and functional. Additionally, during the final product exhibition at school, visitors told me the idea is creative and practical.

The minimalist style is the most popular among young people. The brutalist style (which I ued) was among the least preferred.

I received feedback to improve mainly the aesthetics of the bench, which happened to be more important than the sustainability of the product for those who responded to my survey. I was advised to paint the bench and to add cushions to make more aesthetic and confortable. Some respondents suggested that I should add for compartments.

1- Choice of the wood

2- Design

3- Finishing

Thanks to the exciting summer internship opportunity at Pinocchio furniture in Damietta, I was exposed to many carpentry concepts and design tools that I used in my project. It was an important learning experience, and it allowed to understand the design to production process. Over the time of the internship I learned to:

1. Sketch a design by hand;
2. Use a couple of manual carpentering tools;
3. Use SketchUp for the first time;
4. Deal with master carpenters which confidence, among other things.

I hope to be able to get as interesting as internship opportunities to learn other skills. Also, I wish I could work with other young people on a common project. I have interests in electricity and renewable energy.

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9. « أسعار الخشب و خامات التشطيب لغرف النوم و المطابخ 2022 », أثاثي دوت كوم (blog), consulté le 14 janvier 2023, https://www.athathiy.com/2022/03/wood-furniture-price-Mo.html
10. Ahmed Sharaf,  interviewé par l'auteur, Giza, novembre 13, 2022.
11. Amr Orensa, interviewé par l'auteur, Giza, novembre 15 , 2022
12.  “Définition de la pensée créative, compétences et exemples - fr.cocina123.com.” Accessed February 5, 2023. https://fr.cocina123.com/creative-thinking-definition.
13. I used ChatGPT to write to write in good english the steps to follow to design with SketchUp.