Look for guidance on creating a breakfast bar from reclaimed wood. We have an old outdoor bench that we are looking to re-use to keep some of the house's character. I'm looking at using three 2"x6"x4' side by side (about 15 to 18" deep when all said and done) and supported by some large wall-mounted brackets. Because the bench has been outside, I'm also thinking about spraying with some non-toxic bug killer.

My thought process is to use pocket holes (and glue) to connect the 2x6's together like a flat table top. This is what I'm thinking:

1. Cut the sides of the 2x6's to have an even surface to glue and screw with the pocket holes (as well as minimize gaps in the overall design)
2. Glue and screw the three 2x6's together
3. Sand down top/bottom/sides
4. Use a planer if needed (hoping not having to do this)
5. Fill gaps between boards with wood putty? Repeat sanding as needed
6. Seal with an epoxy or polyurethane

Suggestions on a food-safe epoxy or poly? Some of the wood might have some deeper holes that I'd like to keep for character.

TIA

Sounds like you have it down. Personally i wouldn't do the bug spray step. The most labor will be making the three boards flush where joined. I would start with 60 grit sand paper to get them flush then work your way up to 12 or higher.. I have used waterlox for counters before. I believe the polyurethanes are food safe once cured.

I went through this same process to build my mantle. Pocket screws work great. Otherwise, do a lot of sanding.

Thanks, looking forward to this project

Blech, most breakfast bars are made from grains, fruits, and nuts.

fiber ftw

How much character does this reclaimed wood have?

Do you have access to a jointer or a table saw?

I'd say character is kinda meh when compared to other wood, but we want to use it because it's part of the house's limited history. And the breakfast bar would be something the kiddos would use for eating and/or homework in the future. If we don't like it down the road, we can always swap it out.

I do have access to a table saw, and I'm pretty sure I have friends that have a jointer.