How to Build a Mission Style Blanket Chest

By / May 19, 2025
Home » How I Create Art - The Build Process » How to Build a Mission Style Blanket Chest

When a Colorado Springs client asked me to build a stylish solution to store patio cushions, I knew a mission-style blanket chest would fit the bill.  In this post, I will walk you through how I built this Custom mission-style blanket Chest.

Custom Mission Style Blanket Chest my Benham Design Concepts - Colorado Furntiuremaker

7 Steps to Building a Mission Style Blanket Chest

The blanket chest if built from white oak

1. Planning & Material Selection

  • Purpose: The Chest will store outdoor cushions and open from the top + front for easy access.

  • Material Prep:

    • Select straight, tight-grained lumber for doors/structural parts to prevent warping.

    • Use rustic boards with small knots (filled with black epoxy) for aesthetic.

    • Mill legs from 1.25″ thick lumber (avoid large knots for strength).

Floating Tenons was the joinery of choice for this blanket chest

2. Milling & Joinery

  • Panels:

    • Mill top panels, align with Dominos for glue-up strength.

    • Seal end grain with finish to minimize moisture absorption (for outdoor durability).

  • Custom Floating Tenons:

    • Create wider tenons (using planer/router) for 2″ rails/stiles where standard Dominos are too narrow.

    • Round tenon edges with a 3/16″ radius bit (approximate match to Domino specs).

  • Leg Joinery:

    • Cut mortises for rails/stiles using Dominos + added tongues for extra strength/alignment.

 

Plywood Jig to install hinges

3. Door Construction

  • Dry-Fit Face Frame:

    • Build door inside dry-fit face frame to ensure proper reveals (1/16″ gap).

  • Hinges:

    • Mortise hinges using a plywood jig for precision.

    • Use a 1/16″ shim to set the door offset.

    • Install bronze hinges with stainless pins (rust-resistant).

Assembling the blanket chest

4. Assembly

  • Glue-Up:

    • Use marine-grade epoxy (West Systems) for waterproof, long-working-time assembly.

    • Pre-finish panels to prevent raw wood exposure during expansion.

    • Assemble in stages: back first, then sides/front.

  • Bottom Panel:

    • Notch around legs (cut with handsaw).

    • Attach to cleats to elevate off the ground.

    • Drill weep holes in the bottom rail for drainage.

Torsion hinges

5. Top Lid & Hardware

  • Torsion Hinges:

    • Install to prevent slamming.

  • Steel Battens:

    • Add steel strips with slotted holes to prevent warping on the lid.

Tung Oil finish

6. Finish & Weatherproofing

  • Tung Oil Finish:

    • Thinned with citrus solvent for deeper penetration.

    • Allows graceful aging (no flaking) and easy maintenance (scuff-sand + reapply).

  • Protection:

    • The client will use a BBQ cover during winter.

Clasp to hold doors shut

7. Final Touches

  • Front Doors:

    • Install the clasp to secure the doors.

    • Design allows for an optional shelf (access via front doors + cushions from the top).

Key Features

  • Durable Outdoor Build: Marine epoxy, rust-resistant hardware, weep holes, and elevated bottom.

  • Rustic Aesthetic: Knots filled with black epoxy, Mission-style joinery.

  • Functional Design: Dual-opening (top + front) for versatile storage.

Tools/Materials Highlight

  • Dominos + Custom Tenons for alignment.

  • Titebond III for exterior veneer glue-up.

  • Handsaws/Chisels for precision notching.

I’m the owner of Benham Design Concepts, a mixed media art studio where I design and build custom furniture and other works of art using wood, glass, stone, and various metals.
In this blog, I talk about the art I create, my journey, and the things I learn along the way.

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