Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

Weathered Wood Carboy Crate

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In this tutorial, we’ll show you how to make a weathered wood crate for a glass carboy with a few pieces of pine and some layered stain.

When I was small and still looked up at the world, I loved to go fishing with my Grampop in the tiny creek behind his old farmhouse on a lonely stretch of road in Middlebury, Connecticut.

Every time I would visit, I’d get so excited to catch a fish. I had never caught one before, but I knew that my time was coming soon.

Maybe this time I’d finally get to reel one in!

It didn’t register at the time that Grampop’s creek was only two inches deep and had no fish.

It didn’t concern me that our fishing poles were willow switches with kitchen twine tied to the tips.

I saw nothing wrong with our bent-paper-clip hooks.

And, really, who needs bait anyway?

I’d stand on the creaky old footbridge that spanned the two-foot-wide creek bed, and we’d lay out our line, my hopes as big as my Grampop.

After a long, luckless day of fishing (in reality about five or ten minutes), I’d tire of the fishing expedition, and we’d head back to the house.

I remember he had a contraption in the garage. It was a big glass carboy with bubbling liquid in it. A tube came out of the top and ran down into a bucket.

“What’s that, Grampop?” I said.

“Oh, that’s my special root beer!” He said with a laugh.

Root beer was my favorite! “Can I have some special root beer, Grampop?”

He laughed some more and said, “When it’s ready, my boy. When it’s ready.”

Grampop died a year or so later. I never got to try his “special root beer,” and only much later did I understand that there was no “root” involved with that beer!

After he died, my Nana sold the house and downsized herself into a small apartment in Glastonbury. My parents kept some stuff and sold the rest.

My mom kept Grampop’s carboy, and for the next 35 years it sat in their basement in a cluttered corner of the crawl space.

It sat and waited…

And then, along came Handan.

When we stayed with my parents after moving back to the States in 2013 and even after we moved out, the crawl space was one of Handan’s favorite hangouts. Before she caught the tag sale and Put & Take bug, Handan was already combing through mom and dad’s forgotten junk in the darkest regions of the crawl space.

On one of her excavations, she unearthed Grampop’s old glass carboy.

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We took it home and cleaned it up, and it has since sat in this corner and that corner – sometimes empty and sometimes sprouting sticks or flowers.

All seemed well.

But then Handan’s roving digital eye spotted this:

Source: www.TheDriftwoodHaus.com

And then this:

Source: www.PaintedFoxHome.com

And she wanted it.

Those two demijohns shown above with their weathered wood crates run upwards of $200.

Pfffft. Fat chance!

But she had an old glass carboy.

And she had scrap wood.

And she had a monkey with a hammer me.

I’m sure you know what happened next.

“HEY BABES!”

Yep! I was once again pressed into service to build something she saw on Pinterest.

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Let’s have a look at how I did it.

Weathered Wood Carboy Crate

Supplies Needed

Cut List

1 x 3 board

  • (4) 11 1/8 inches
  • (4) 12 5/8 inches

1 x 2 boards

  • (3) 11 1/8 inches
  • (2) 8 1/8 inches
  • (4) 15 13/16 inches, mitered both ends at a 39 degree angle and measuring 14 5/8 inches from long tip to short tip.

2 x 4 board trimmed to 1 1/2 x 1 1/2 inches and ripped at a 45 degree angle

  • (4) 17 1/2 inches

Here are the pieces, cut and laid out:

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To cut the triangular vertical supports, I set the table saw blade to 45 degrees and cut the squared-off 2×4 in half the long way.

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Once the pieces were cut, assembly was a snap. First, I made two frames like the one shown below using the 1 x 3 pieces.

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Then I put some wood glue on the ends of the shorter pieces and brad nailed the frame together.

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Next, I added the vertical supports and secured them with glue and brad nails.

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I attached the two 8 1/8 inch pieces as shown below with glue and brad nails.

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Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

Next, I laid the three base slats, leaving 1 13/16 inches between the slats. I brad nailed them in place.

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I added the angled supports and secured them with glue and brad nails.

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The second frame sits on top of the angled supports. I secured it with glue and brad nails.

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

And that was it for the build.

But I needed to sand the edges and corners to take away that “newly-assembled” look. I used my mouse and really gave it a good sanding, especially the corners.

To give my carboy crate the weather wood look that Handan was wanting, I used three stains:

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The Special Walnut gives a soft brown base upon which I build with Weathered Gray and Kona. Here is the carboy crate after the Special Walnut. I just applied it normally and wiped off the excess.

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

I let the first coat dry for about an hour, then I applied the Weathered Gray. I used much less Weathered Gray, and I applied it almost as if I were dry-brushing it on. I didn’t cover every square inch with it – I left some areas with just Special Walnut. I also worked on one face at a time, applying it and immediately wiping it off.

Here’s how my weathered wood carboy crateย looked after the Weathered Gray. As you can see, the gray is subtle. I wasn’t trying to stain it fully gray.

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

Next came the Kona, and that’s the magic. I didn’t leave the gray to dry, but started right away with the Kona. Using a small rag, I applied only tiny amounts of Kona to the wood – a dab here, a streak there – and immediately rubbed it in and blended it with the two other colors.

This part of the project was art.

I worked on small sections at a time, applying a little, rubbing it in, maybe adding some more. I worked around the carboy crate, streaking here, darkening small patches there, until I achieved what I thought was a good weathered wood look.

The process is actually very simple.

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

Since the crate will be living inside, I didn’t bother finishing it with polyurethane. Any more natural “weathering” will be entirely welcome!

When Handan saw her new weathered wood carboy crate, she was thrilled!

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

The weathered wood effect turned out great.

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

We even decided to use the same technique on a farmhouse trestle table I built for our new deck.

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

I think my Grampop would be happy to see that his “special root beer” glass carboy has a nice new home.

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

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Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

Weathered wood carboy crate | DIY Vintage demijohn bottle crate | DIY weathered wood | How to create weathered wood look using stain | DIY demijohn crate | DIY Farmhouse decor | #TheNavagePatch #DIY #weatheredwood #easydiy #Rustoleumstain #Upcycled # Repurposed #HowTo #Demijohn #Vintage #Farmhousestyle #Farmhousedecor #Farmhouse #myrustoleum| TheNavagePatch.com

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18 Comments

  1. I love this Greg, but what I love even more is that you’ve preserved the memory of the time you spent with Grampop. I think he’s smiling down on this ๐Ÿ™‚ Can’t wait for the video!

    One question though: how many ‘special root beers’ did it take to complete this?

    1. Thank you, Sara! I’ve graduated from special root beers to dry martinis. This is definitely a one-martini project! ๐Ÿ˜€

  2. You did your Grampop proud! He’s watching you. I watch those Psychic reality shows. Especially the Seatbelt Psychic reality show.

  3. Ohhhhh I Like This! Ilikitalot ๐Ÿ™‚

    Now I think it is time to start making Navage Patch Pumkin Ale.. Hmm.
    Well Done!

  4. man my hormones must be out of whack I started bawling reading ’bout you and gramps, you have been going down sentimental street a lot lately but I do love this I always wanted one of those carboys the closest I ever came was a cracked plastic 5 gallon water jug lmao xx

  5. If Handan ever finds another one of you at the Put and Take, make sure she picks him up. I could definitely use a handyman at my place. I get lots of ideas, put so far my skills set doesn’t keep up. I really enjoy your post.

    1. LoL, you’ll have to get in line, Georgia! If Handan finds another me, I’m putting HIM to work, so I can have some rest! ๐Ÿ˜€

  6. Yes, the weathered wood did turn out great! So did the crate! It really looks good. WAY better than those other 2. Why is it called a carboy? We have one that has collected pennies for YEARS but now…..I need my own monkey with a hammer!

  7. I love the grampop story, thank you for sharing it! I love that you have the carboy to remember him.

    Weathered Gray is my all time favorite stain. I have used it on several projects in combination with acrylic paints, but seriously never thought of mixing other stains with it. Filed that little nugget in my “to try” bin… I’ve got a couch-back table idea rolling around in my brain that will house my soon-to-arrive GlowForge and possibly my dogs’ crates (small-ish home living is new to us, we’re definitely brainstorming multi-use functionality items)… I think it might need the 3-stain treatment whenever I extract it from my brain and build it with my hubby.