Step 4: This is actually the trickiest part. Using gorilla glue, glue the strips together, wood side facing out. I use a paint brush to paint "water" along where the gorilla glue will be. You are gluing three boards together forming a U shaped faux beam as shown. The 4" strip upside down on a covered (glue oozes out) work area table or bench. The two 6" strips facing out will sit flush with the 4" strip on the work table. Glue one side, as you glue you will screw the 2" screws as if screwing the pieces together. This will pull the pieces taunt. The hard part here is making sure the newly made 6" side is flush. Don't worry, after you have glued both sides on, while the glue is still wet, you can turn right side up remove and reposition your screws as needed until its flush and cinched in tight. I use latex gloves when working with gorilla glue.... it's messssyyyy. I use screws sparingly as it leaves holes that will later need to be filled. Once it's flush, with the glue still wet clamp it together as tight as you can, without denting to boards to badly. You may want some additional 4" scrap pieces to keep the sides parallel. As the glue sets, it foams and oozes out on front and inside. So don't walk away from your project for too long. You want the bulk to be on the inside, but some will make its way out the top too. Try to scrape this off or smooth it down before it sets completely, it is difficult to remove after setting. and also difficult to cut into. YOU DON'T want to be able to tell these are seams on the finished product. Let material set. Remove clamps and screws and plug the holes with wood putty.
|This is what happens when you get carried away with the wire brush....beautiful!|
|This is after the gel stain, but before any gray wash. As you can see, it would be fine to leave as is...I like the weathered look of gray wood.|