More Pews

The organic nature of our ministry offers some unique opportunities for creativity and collaboration. We heard that Most Holy Trinity Catholic Church had some old pews taking up space in their soon-to-be-demolished shed. The church has been in the neighborhood since 1848, and we've worked with them on the Hyde Park Festival and gardening. We already have some experience making furniture out of recycled pallets, so we were interested in getting the pews. So we called them up and checked them out, and they looked usable. Everyone agreed that the craftsmanship on the old pews was too good to waste. Plus, they were a great piece of history (although no one's sure on the exact age, they're at least 80 years old). But we didn't have a place to store them, or a product to make with them. Also, I was getting married and wanted to use the pews for my outdoor wedding in Hyde Park. So Holy Trinity held on to them for a few weeks. In that time, they also invited us to sell our products at their trivia night fundraiser. We decided to build a custom piece out of the recycled pews and sell them at the trivia night, giving half the cost to Holy Trinity (plus a portion of our other sales).

After some thinking, we decided on a hall shelf; something a little more unique than a bench, and a little smaller, too. The construction is pretty basic, but sturdy, and retains the original, aged finish of the oak. So after the pews did their time at the wedding, we broke them down, denailed them, cut the seats to our shelf sizes, and assembled it. After scrubbing them down with some Murphy's oil soap, the wood shone wonderfully.



The finished product.  The photo on the left shows it in action!




What else have we made of pews? Well, we've made a conference table. One lady custom ordered a bench.

Pretty much just a short pew, but with a shelf added to the bottom.

I made a storage bench for my wife.



The seat lifts up to reveal a storage area.



And, we've made a pretty fantastic candle holder.

Actually made from the same pews as the conference table.  It's the base of the end of the pews.

New Pallet Products and Etsy!

This past year has given us some opportunity to continue to experiment with recycled pallet wood. The Sun Cafe and Market is set to open sometime in early 2013, which will give us space to display our wood products. In the meantime, we have started an Etsy account and will be putting on one-of-a-kind items from time to time. In case you didn't know, our Products with Purpose are made in the Opportunity Center here in Hyde Park.  Our missionaries learn to work with their hands, and the sales (and skills) support the ministry.  It also gives us skills we can then teach to people ready to change their lives.

Here are some of the things we've made in the last year or so:

 



Recycled Pallet Candle Holders



Candle Holders

Simple, rustic, and artsy. A couple different styles. Sold pretty well at the Old North Christmas Bazaar.





Recycled Pallet Night Stand Dresser



Rustic Night Stand Dresser

This was designed by our executive director. Has a rough finish and simple, rustic construction. The lap joints were nailed together.



Recycled Pallet Hall Shelves



Hall Shelves

We tried to find something that would use some smaller pieces of wood. We made a sleek, modern one, and a more traditional/country one.

Patio End Table

Patio end table

This was a custom order piece. Sort of a combination of two table designs we already had. The frame is mortise and tenon joinery, while the slats are simply screwed and glued. I really liked this design because it was sturdy and attractive, and matched our deck chairs perfectly.

Crazy large sliding door

Sliding Door

This was another custom order. The door was two inches thick, 89 inches tall, and 40 inches wide. It weighed A LOT!  The mix of woods gave it lots of character.



Recycled pallet picture frames, and Mark Goodwin Photography.



Picture Frames

Used best to house Mark Goodwin's photography.

Recycled pallet stools with upholstered seats

Stools

A custom order from someone in the community. The design was based off a really simple stool that was in the Opportunity Center when the building was donated. Mortise and tenon joinery. We tried to use oak as exclusively as we could in these.  Getting the stain color right was tricky, as the customers had a table we were supposed to match. The table was really really dark, so we didn't quite make it, but they compliment very well. Also, they were our first upholstery job.

Recycled pallet bookshelf

Book Shelf

This thing is heavy! I tried to make something that really emphasized the material we use, which is recycled pallets. So it's chunky, there is quite a mix of woods, and plenty of character.  The sides are framed panels.

Pallets and Pews

We enjoy taking custom orders in the Opportunity Center woodshop. It gives us a chance to try new things and expand our skill sets, which means we can make better and varied products, and we have more skills to teach. All of our missionaries who work in the woodshop were amateurs, so we've been learning as we go. We try to fund most of our operation with the products we can make with our hands, so improving the quality and variety of our products allows us to become more sustainable.

Our biggest indoor custom order came from Alderman French of the 21st ward, which is our neighboring ward to the north. The ward has purchased an old church building, and is in the process of turning it into a community center, that will also include offices and meeting spaces. Since it was a church, it was full of old oak pews. Alderman French asked us if we could turn the old pews into a conference table. Of course, we said yes.

The project took an exceptionally long time, as the Opportunity Center was very busy from Spring through Summer, and we made the table for free. When we finally got down to it, we discovered that the backs of the pews, which were nice and wide, were bent plywood, so they would not make good table tops. The seats, although upholstered, were solid oak. So we disassembled the pews, cut the seats to a width that would fit into our planer, and planed them down so they would be nice and flat. We ended up gluing five seats together, to make a 5 ft. by 8 ft. table top.

We originally thought we could use the carved oak ends of the pews for feet, but found it to be a huge problem logistically. So we ended up building a supporting frame out of the recycled pallet wood.

Attaching table tops to their frames is a delicate business, as wood swells and shrinks with changes in humidity. Furniture makers have discovered a variety of ways to compensate. We, however, were unaware of all that. So we got decorative bolts and bolted the table top onto the frame. It gave the table a slight industrial feel, which we felt worked, as it was all recycled material.


We stained the whole table a nice dark brown, and sealed it with polyurethane. The table top was exceptionally beautiful, as it was furniture grade oak. A lot of the wood from the pallets looks great, but to get free furniture grade lumber (although it cost some processing time) is a sustainable way to make more traditional looking furniture.

The Alderman loved his table, and we enjoyed the opportunity to make something unique and learn a bit as we did. This coming winter, we are going to try to develop more indoor products. If you have ideas of wood products that you think would be desirable made from recycled wood, and some price ranges, you can contact our executive director, Dr. Terry Goodwin, at terry@sunministries.org, or leave a note on our Facebook page.