ok .. were getting close now ... as i wrote back on july 28th, theres a lot going on in the shop. for the last week or so though, trevor and will and i have been pulling the final pieces of the pool table together. pool tables are alchoices a challenge because, typically, we havent built one for a while. our last one was in 2008 ... holy cow, no wonder we couldnt remember what we were doing exactly, and they are all different ... were wrapping this one up, and, wonder of wonders, well be starting another one in a couple of weeks. hopefully that one will be a breeze. .. click the photos to enlarge them ...
like most things here, we took something and did something to it.
natural irion walnut and quilted big leaf maple
what we took was the pool table below, dropped the tapered legs, changed the inlays from baseball inspired to geometric and had at it. the proportions, moldings and palette are pretty much the same, but the result will be different ...
the one above we built in 2003, so no one working with me now was working with me then. but fortunately, that table is local and, coincidentally, the client requested that we level it up as it was exhibiting a slight roll to one corner. after studying the roll, (it took 3 or 4 racks), we determined that the one corner was in the dead center of a +/- 30 clear span and either the thick carpet there had crushed or the joist had sagged ever so slightly. a piece of 1/16th inch veneer and two playing cards under one leg and we were back to level. it was a bonus, as we got to check it all out and remember how to build it.
like anything, you start with a bunch of parts. i never counted them, but trust me, there were a bunch ... our trusty companion is still, after 23 years of pool table making, (15 tables total) an article by paul bowman that first appeared in fine woodworking in 1989 ... i give you the link here. pauls table was different than most of ours, but the information applies (still) and if you study it, i think its all in there somewhere.
we typically start with a leg mockup ...
and in this case, we made the mortises for the inlays and the inlays for the 16 leg pieces, but held off on gluing the inlays in until we were ready to do the finishing ...
our assembly system is a hybrid system of bolts and steel plates and captured nuts, (like for bed bolts), and i really need to document that for the future .. trevors got it dialed in now so as long as hes around, im good to go.
i have documented the rail process a series of steps below that define the playing area (44 x 88 in this case), and make the balls behave and the pockets the right size.
the rails are constructed in two pieces ... ive got a very detailed cad drawing with dimensions and angles and ill post it here at some point ... the steel plates you see in the poplar above are for the rail bolts that come up through the holes you see in the slate below and lock the cushions firmly in place so the balls bank properly.
after we add the profiled rails to the polar subrails, we cut them to length using standard dimensions for each size playing area.
first we install the inlays, spaced in all cases at 1/8th (long rails) or 1/4 (end rails), of the playing area. in this case 11" starting out from the center of the side pocket and the middle of the end rails.
then we add the rubber using yellow glue and masking tape with the goal of having the point of the cushion one and 13/32nds (1.40something) of an inch above the surface of the felt so that they are not too high ... (ball does not rebound with life and kind of thuds) .. or too low ... (ball rockets off the table when struck too hard). .. a vitally important detail ...
then you have to figure out how to drill the holes for the pockets .. we do em like this, except on a full size table where we have to raise the drill press up on a platform.
then you have to drill for the bolts that hold the pockets in place ...
then you get to put it all together and bolt it all to the slate and mark out the pocket angles ...
above, i give you the keys to the kingdom ... the order in which to do all this stuff. this is my 3rd and hopefully final iteration of this list.
after marking the angles using the standard measurements and angles from pauls article and a couple of jigs we have made, we cut them on our chopsaw, all on compound, fussy angles. the ends of the rubber than get different rubber cushion facings and then the felt is applied ... well cover that when we get to it ... soon
update 8/22
i still havent posted the felting of the rail details, but i hope to get to that tomorrow or maybe over the weeked. the table is finished now and it will be leaving for virginia next week on tuesday
we set it up for a final check yesterday, using a piece of blue felt left over from another project. i only wanted to stretch the real camel piece once, when the table is set up for real ... plays great and im happy with the new design.
There is nothing closer to a mans desire than a juicy delicious Prime Rib. Well, almost nothing. :-)
First we cut the rib bones achoice from the meat. Well tie them back on later because they add a ton of flavor to the meat while its cooking. 
Here are the spices I have decided on for this yummy Fathers Day roast.The Everglades seasoning is something we picked up on our Florida vacation. It has a strong but very nice sage taste. 
Lets mix them up so we can hammer this prime rib with flavor! 
Next we coat the meat with regular yellow mustardthat everyone has in the refrigerator. 
We will completely cover the meat with these spices. 
Then we heavily salt and pepper the rib bones before tying them back on to the meat. 
Back on the bone! 
We tie it up tight! 
And back into the refrigerator it goes to sit overnight and let the meat absorb those flavors. 
The afternoon of the following day, its time to put it in the Grilla Pellet Smoker.(www.mygrilla.com) We will set the grill for 275 degrees F.We will be using American Hickory pellets.
This Maverick digital meat thermometer with remote unit makes cooking it to a perfect medium a breeze.We will bring the meat temp to 140 degrees F. 
Tell me this isnt making your mouth water! 
Now we cut the butchers twine and prepare to carve this luscious smoky prime rib.
Cooked to perfection, exactly the choice Connie and I like it. 
Dinner is served! 
The following day we vacuum pack the leftovers in meal size packages and into the freezer they go. 
The Food Saver works great and keeps food good in the freezer for up to 2 years. Not that this yummy food will last that long. 
We had enough leftovers for nine more meals for two. We will be enjoying this prime rib for many meals to come. I hope you liked this Fathers Day Prime Rib post.Thank you for stopping by my blog and please consider being a follower.Steve
When last we left you a couple of weeks ago, Will was heading down the homestretch on banjo #3, thinking he was making a Christmas present .... In the end, he got an extra couple of weeks that he really didnt need. It turns out its to be a birthday present, the 20th of January to be exact .... It took the pressure off and allowed him some extra time to do a really super job ... Looks cool; sounds even cooler .... one of the happiest instruments I have ever heard ... Heres a one minute concert clip ... Take a bow Will ...
12/14
12/31
He finished it Wednesday, we photographed it today ...
For Mackintosh H.M.Swan .... 1/20/2011 is his birthday
Gold abalone in pearl inlays ...
Back view ... Keep in mind that this is actually a mini banjo with an 8" head and a shortened scale and fretboard ....
from the video ... check it out
And the coup de grace is the nameplate ,,,, made by Will on the CNC with a 60 degree bit .. the brass plate is about a 1/2 " tall ...
the one above we built in 2003, so no one working with me now was working with me then. but fortunately, that table is local and, coincidentally, the client requested that we level it up as it was exhibiting a slight roll to one corner. after studying the roll, (it took 3 or 4 racks), we determined that the one corner was in the dead center of a +/- 30 clear span and either the thick carpet there had crushed or the joist had sagged ever so slightly. a piece of 1/16th inch veneer and two playing cards under one leg and we were back to level. it was a bonus, as we got to check it all out and remember how to build it.
