Making the Cargo Bale

[Captain Jack Sawford]

Photo 1 - I created a rectangular wooden frame of pine 2x2s reinforced with metal corner brackets. 

Photo 2- I reinforced the top essentially making a bench so that once finished it could serve as a seat.

Photo 3 - I reinforced the bottom but added a hidden hatch so that the interior of the bale could be used for storage. I couldn't justify something so big as just a seat or just as a set piece, so it is where we hide farby modern things we have to have, such as the drill for the screws assembling the tables cutter made, or the current med kit, etc.

Photo 4 - The working hatch underneath with simple hinges and locks. 

Photo 5 -  I wrapped it in two layers of cushion foam and stapled it to the frame, careful to staple in certain places so that it didn't effect the overall cushiony look or feel of the bale. The cushioning surrounds the entire thing except the bottom, covering only an inch or two of the bottom at the sides. This also serves to hide the fact the bottom isn't cushioned.

Photo 6 - I used two layers of canvas to wrap the entire form.  This way should the top layer rip through use or wear it wouldn't show the foam underneath. I pulled it tight, cut excess, and carefully sewed the fabric so it covered the foam tightly. I left a flap of canvas underneath to cover the wood of the hatch. It doesn't completely hide it, but no wood is exposed so if it happens to tilt or tip people are less likely to notice it's true nature. I then chose an East India Company logo that I painted with a small brush and a toothpick for details. I picked the bale number for a band I liked because why not. 

Photo 7 - Decided upon using an East India Trading Company bale mark. I painted it on using a small paintbrush and a toothpick to avoid smearing the paint on the rough canvas.

 

Photo 8 - I added the ropes. I couldn't tell from paintings if the ropes were interwoven with one another, or just looped around. Interwoven seemed more secure to me so that's what I did. They end underneath the bale, where the ends are whipped, stapled, and sewn to the foam on the edge of the bottom. The ropes are also sewn together where they overlap, and sewn in places, secretly, to the fabric of the bale.

Photos 9 and 10 - The cargo bale photographed in the wild.

[Stynky Tudor]

Well done, very cool, great execution!

William and I were just talking/brainstorming about (how to) do something similar.

[Mary Diamond]

Nicely done! Had you applied any fabric or wood treatment to protect the piece?

I had come across this video while wandering through bushcraft videos, and was intrigued by the possibilities for protecting a wide variety of materials (canvas, rope, etc.) without substantially changing their color (as with Townsends video on oilcloth). NeverWet by Rustoleum is also in our paint locker, awaiting a trial…

 

[Captain Jack Sawford]

I didn't treat the wood or the fabric as if it does rain we would bring it under one of the canvas awnings at our encampment but also because it didn't occur to me!

[Stynky Tudor]

I've moved a bulk of the discussion to "Crafting Kit".

 

[Mary Diamond]

Thank you, sir…