Building a Bench with a Stone Leg

A Unique Woodworking Journey

Woodworking often blends creativity, craftsmanship, and problem-solving. In this project, I set out to build a bench unlike any other—one that incorporates a massive granite boulder as a leg, refined joinery, and an elegant wooden arch. This custom bench project was built for a Colorado Springs Client. Here’s how it all came together.

The Stone Leg: The Most Demanding Part

The project began with the most physically challenging task—working with the granite boulder. Since the stone was too heavy to lift alone, I used an engine hoist to move it from my truck. Once positioned, I scored the base with an angle grinder and broke off the excess with a coal chisel to reduce weight.

But that wasn’t enough—I wanted the bench to be movable by one person, so I spent an entire day hollowing out the rock with a 4-inch angle grinder. By the end, my arms felt like they’d grown three sizes!

Inspiration Behind the Design

The idea for this bench came from architect Erick of 35×40 Design. He once designed a house where a boulder was craned through the roof to become a fireplace. That got me thinking: How can I incorporate raw stone into fine woodworking?

After some brainstorming—and a hike through Oregon’s Cascades—the vision clicked: a bench that bridges organic stone with precise joinery.

Carving the Bench Top to Fit the Stone

With the rock hollowed and manageable, I milled lumber for the bench top. The next challenge? Carving an opening in the wood to fit the irregular stone shape.

1. Initial Layout: I drilled holes and chiseled out the rough shape.

2. Tracing & Refining: Placing the board over the stone, I traced the outline from underneath.

3. Power Carving: Using an angle grinder with a carving disk, I removed material up to the marked line.

4. Final Fit: As I got closer, I switched to rasps and files for precision, ensuring a snug but slightly loose fit to allow for wood movement.

Constructing the Wooden Arch & Supports

The bench’s arched backrest required laminating thin walnut strips around a plywood form. After gluing, I:

• Cut the arch to length with a Japanese pull saw.

• Shaped the ends to match the leg’s angle using a bandsaw and hand plane.

• Hand-cut through-mortises for the cross braces, carefully chiseling to match the arch’s curve.

Assembly & Finishing Touches

Before final assembly:

• I reinforced the hollowed stone with spray foam to prevent cracking.

• Added a steel bracket to secure the wood to the stone, carefully drilling and welding custom-fit rods.

• Applied a water-based dye to the mahogany to enhance its grain.

Finally, I epoxied the arch in place, using screws (later replaced with decorative dowels) for clamping pressure. The last step was bolting the top to the stone—tight enough to hold, but loose enough to allow for wood movement.

Final Thoughts

This project pushed my skills in stone carving, joinery, and design. The result? A functional yet sculptural bench that blends natural stone with handcrafted wood.