Crafting Okesutora's Custom Seating: A Journey of Innovation and Tradition

When Mymy Nguyen, the creative force behind Okesutora, reached out to me for custom seating and a bartop for her new restaurant in Downtown Sacramento, I knew we were about to embark on a project that would stretch the boundaries of traditional craftsmanship. Okesutora’s vision was to blend minimalist Japanese aesthetics with intricate details—simple yet sophisticated, with every element meticulously crafted to perfection.

While the design was steeped in tradition, the process of bringing it to life was anything but ordinary.

Tradition Meets Modern Craftsmanship

One of the core challenges of this project was creating 8 benches that adhered strictly to traditional Japanese woodworking methods—without a single metal fastener. This called for reliance on friction fitting and glue assembly. The legs were joined to the bench tops using through mortise and tenon joints, each tenon carefully wedged with additional pieces of white oak to ensure a solid, long-lasting fit.

Achieving this required a perfect blend of old-world craftsmanship and cutting-edge technology. We used a duplicator on the lathe to ensure that each component was an exact match, while CNC milling allowed us to cut the mortises with precision down to the millimeter. This careful combination of traditional woodworking principles and advanced techniques enabled us to create benches that were as structurally sound as they were visually authentic.

A subtle but impactful detail was the slight curvature in the legs and back spokes, which added a touch of elegance to the design. This curvature softened the lines of the benches, giving them a refined look that complemented the simplicity and purity of Japanese style.

The Steam Bending Saga: Innovation on a Grand Scale

The most demanding aspect of this project was undoubtedly crafting the curved backrests. Steam bending is a technique with a rich history, but working with thick white oak proved to be a formidable challenge that required both patience and ingenuity.

Our first attempts were met with frustration. I began by soaking 1 1/4-inch thick oak overnight, then steamed it for two hours before attempting to bend it into shape. The result? A loud crack as the wood snapped. Not deterred, I tried again—this time soaking the wood longer and increasing the steam duration. Although this attempt yielded slightly better results, with one side bending successfully, the other side still broke under pressure.

With the project deadline rapidly approaching, I knew a different method was needed. The solution involved cutting the backrests into 1/4-inch strips. These thinner pieces were easier to work with: I steamed them, bent them into shape, and laminated them together on a custom mold. But getting to this point required building an incredibly complex steam-bending jig that took up an entire 8'x4' workbench. This jig was essential to hold the wood in place and apply the necessary pressure to achieve the desired curves. Needless to say, we used every clamp we had for this.

The process was labor-intensive, involving multiple steps of steaming, bending, drying, and gluing. After the lamination was complete, extensive trimming and shaping were required to refine the backrests to their final form. Despite the challenges, the result was a beautifully curved backrest that not only met the design specifications but also stood up to the demands of everyday use.

The Bartop: Where Precision Meets Perfection

The bartop at Okesutora was another highlight of the project, presenting its own set of challenges. Spanning an impressive 28 feet, it was crafted from white oak slabs that had to be seamlessly joined. Instead of a simple butt joint, I opted for a more traditional approach: dovetail joints, designed and cut with the aid of CNC software. This method required an extraordinary level of precision—the joints needed to meet with a tolerance of just .01 inches, leaving no room for error.

The result was a bartop that not only delivered in terms of structural integrity but also enhanced the traditional aesthetic of the space. The dovetail joints provided a visual connection to the Japanese design principles that guided the entire project, while the rich texture of the white oak brought warmth and character to the restaurant’s interior.

A Project to Remember

In total, the project took 1.5 months to complete, with countless hours dedicated to perfecting every detail. The benches and bartop at Okesutora are more than just functional pieces of furniture—they are a testament to what can be achieved when traditional techniques are combined with modern innovation. The project challenged me to push my craft to new heights, to experiment with new methods, and to stay true to the artistry that lies at the heart of custom woodworking.

This project remains one of my favorites to date. It's a perfect blend of craftsmanship, creativity, and the relentless pursuit of perfection. The finished work at Okesutora has even been featured in Sactown Magazine, a recognition that underscores the unique atmosphere and design that the restaurant brings to Sacramento’s dining scene.