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Senin, 30 Januari 2017

tune up that bandsaw

we just finished a project for a local interior design firm that involved making 12 new feet for 2 big couches whose feet were not really in proportion to the rest of them, or to the room where they went ... the new feet are 7" in diameter, 7" high. we glued up some blocks from8/4 and made a sample and a template for the duplicator and had at it. before will could start turning them, i cut them to length and round for him. will had recently tuned up the bandsaw, adjusted the guides, etc. etc., but i didnt realize what a good job he had done until i cut the blanks ... square ... straight ... cut after cut, through 7 " of maple ... click the photos to enlarge them ..
in response to the comment below, i am posting a link to the bandsaw blades we use. THE most important part of the tune up is a new blade from doall. weve tried many brands i wont name, but these are, in our opinion, THE best. i have to go to the shop to find the exact info ... next is to adjust your guides close to the teeth and square your fence to the table and the blade ... fussy stuff but worth the effort. see the last photos below.
this is how they lined up across the top of a stack 3 high ... barely a 32nd difference across the tops.
the chips flew during the rough out stage ...
and made quite a pile ...
first coat of stain ... after distressing we used a second coat of english brown mahogany lockwood water stain. then a coat of oil/poly, then gel stain on the lathe spinning on low speed. the final coat of satin poly was brushed on with the feet on the lathe, and then they were transferred to the finish room to dry where you see them below.
all in, all done ... they will be installed to the couch frames with 2 - 8" timberlock screws per foot
in the photo above, you can see a stack of 9 - .1" veneers cut sequentially and sanded after from one piece of 8/4 walnut. and 4 - 10.5" wide curly hard maple slices also from one board.
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Jumat, 20 Januari 2017

Catching Up

Well, so far, for a refreshing change, its been a pretty busy month ... We finished what I thought at the time was a pretty big claro walnut slab table, 3 x 10, below. Turns out, its not so big. Well be able to put four of them, probably with chairs, on the table (thats just half of it above ) we are currently designing and building with Steve Holman of Holman Studios ... The first of two tables in this commission will be 26 x 9 and then we have another tiny one to build that will be only 8 x 20. Steves shop is just down the road from ours and we often collaborate on projects like this one and like this project we did last year. More on the big table later this weekend ....
Also, today, Will and Ashley are on their choice to New York City for the weekend and, while they are there, they will drop off the 10 walnut chairs in the photo above to the client who got the black Art Deco vanity a couple of weeks ago. They looked really good with the table above, but the client received their Nakashima table yesterday and Im anxious to see how they look with that. Last weekend, I went to Boston to drop off three tables to a designer I sometimes work with, Jennifer Palumbo. You can see two of them in the photo below. And then I spent the weekend visiting my sister in Rockport, just up the coast by Gloucester. While I was there, we made an afternoon of the Peabody Essex Museum in Salem with the Ying Yu Tang Chinese house ... Spectacular museum with a great collection of North Boston shore Federal furniture, ship models, and other fascinating stuff.
Classic Rockport, motif #1 Roy Moores LobstersOne of the Seymours.
Also, in Boston, I visited my Brother in laws letterpress print shop, Firefly Press, (more on that later ... It was really cool) and dropped a small table/mockup Sam made at the home of the cockatoo chairs ...
Were about a day achoice from finishing the king size bed with the metal inlays we have been working on. That has been an immensely rewarding project on a number of different levels. Love the clients, Will did all the turning and carving and some of the inlay work, Sam did all the metal finishing and coloring, Trevor did a fantastic job with the CNC work on the inlays, we learned a whole lot about waterjetting, (the post just below this one) which was fascinating. As we were working on that, Jim occasionally entertained us all with his new coat.
The duck inlay parts ...
The week before last, we installed one of the two tv cabinets we made back in the fall in the This Old House project. Looks great the big one will go in the week after next.
For a 37" flat screen
Yesterday, a colleague asked me to join Linked In, which I did...any Linked In folks out there? Dont know much about it but it seemed like something I should do ....Comments? If you haveany experience with it. Kind of like Facebook for business people it seems ... Anychoice, its a really rainy Saturday.... no golf or tennis today ... Wheres that Hunter Thompson book Im reading?....More later if it keeps raining ...
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Selasa, 20 Desember 2016

You Cant Leave Em Alone For Even a Minute

Will and I went home for lunch the other day and when we got back, Trevor had us rolling in the aisles with his new Halloween decoration. He was in the middle of a big mdf run and had an extra piece so he whipped this up for the kids in his neighborhood ... He says he has some glossy white spray paint for the full effect ... BOOOOOOOOOO ! ... Loved it
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Selasa, 08 November 2016

another claro walnut slab table

up next, another claro walnut slab table.  this one will be about 52" wide by 102" long after i make the final cuts tomorrow. the base will be welded steel, similar to the one on the desk we made in july  and the dining table we sent to aspen in august.  click the photos to enlarge them.
sam is ready to weld the base pieces tomorrow, and the jig is ready to go too.
the process of moving these tables from the rough slab to the final dimensions is one that we approach very slowly, a bit at a time.  once you cut something off, theres no sticking it back on again.  and, a lot of the time, we disagree amongst ourselves what is the best cut to make.  we try to involve the client as much as possible, but its often hard to portray in photos what exactly it is that we see in front of us. 
 in this case, we started by trimming off the legs, and obvious choice.  we did leave a little bit of the crotch showing on the face side, and we may go back and trim that a bit more before we finish.
 we then cut some of the cracked portion off the far end as the table wants to be around 102" long when we finish it.
we then did some rough planing and splashed a little alcohol on it to check the figure .. looks good.
we then made a 2x4 mockup of the base and checked the proportions ... now, as you can see from the top photo in this post, weve moved the slab down to the shop now that the pool table and the oak table are gone.  itll move right along now ... updates as we go ..
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Minggu, 06 November 2016

the kitchens in

this week and last, we moved the curly maple kitchen we have been working on from the shop to its new home.  it was trickier than it looks.  typically, templates for the counter tops are made after the counters are installed, but because of the timing, and, in particular, the long lead time on the sink, we had to make the templates and the sample sink as we started the cabinets.  click the photos to enlarge them ..
before we left the shop though, we had to finish up the plate rack cabinet.  since we actually hadnt built one of these, we made a prototype section with a tablesaw cove to keep the plates in place, (run the board on an angle over the blade raising it a little at a time). BE CAREFUL !!
then, we got to the site, which is a 1920s era large colonial that our client has been working to restore for several years.  we used the slate templates to locate the cabinets and then brought in the slate, which was cut and milled at sheldon slate in granville, just across the line in new york state ... i posted photos of their facility when we first started this project a while back.  there are more early pictures of this project at that link.
the slate was delivered and installed by tom mullan, (seated here), and his crew, sheldons installation subcontractor, who was the epitome of professionalism, and maintained complete calm as the ineveitable little problems we encountered were overcome.
 
they had a slick little four wheeled dolly that enabled them, and us, to move the +/- 450 pounds pieces into place.
 
ta dah on the corner piece ... it fit perfectly against the wall even though there were some old house, out of square corners that we had dealt with when we made the templates.
next came the sink cabinet below.  we had a one dollar pool in the shop where we all guessed the weight of the 42" x 21" x 13" deep slate sink.  trevor took the loot with his guess of 425 pounds ... it said "430 pounds" on the crate.
complicating this operation was the fact that the sink was wider than the opening for the doors.  we made the corner section removable so that we could slide the sink into place and locate it (using the mdf template) and installing the doors and returns after the counter was in place.  we only had to slide the counter back once to relocate the sink about an 1/8th of an inch so that the 1/4" counter overhangs were consistent.  i was some glad when that process was finished.  there was no margin for error.
 
we returned a couple days later with the long, glass doored upper cabinet that will built, and that part of the installation went very smoothly.
 
all in, all done, except for the last piece, a 42" marble table that fills the space between the two counters.  that goes in tomorrow, just in time for the fundraiser party the client is hosting saturday night for the local dorset nursing association .. it should be a great party!  more pics when we are totally totally finished.
trevor put the finishing touches on it today ...
there are a lot of interesting details in this house, like the island we made back in may, (another challenging project), the soft corners on the wall openings, the owner made concrete floor tiles, and the curving steel and marble stairchoice...
all done; the tables in ... 
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Rabu, 12 Oktober 2016

Packing Up Moving Back


For those of you that follow this blog, and others who stop by from time to time, I thought I would let folks know that it will be awhile before I post another project. We have sold our home, and shop, in West Tennessee and moving back home to the Greater Cincinnati area after being here for the last 9 years.  I moved here for a work transfer and have been retired now for 18 months. 
The big draw of course is family, 3 children, 4 grand children, brothers, sisters, nieces, and nephews.  We were fortunate in this economy to sell this house so quickly (less than 3 weeks) and the home we are purchasing was under construction and we’ll be moving in Christmas week.
So for now, my “projects” involve packing tape, boxes, and filler paper, but as others have said, it is giving me a chance to clean out and see what exactly I have collected over the past 9 years. 
As mentioned in previous posts, some of the power tools are gone. The workbench as well, that will be the first project in the new shop, the Benchcrafted Shaker style bench so I will post when that project gets underchoice.
I will be back in the basement again, and have already marked my space.  The type of work I do and the increased use of had tools will allow me to set up a nice area to build the things I enjoy, and the best part is I will be able to teach my grandson’s the joy of working with wood. 
Merry Christmas and Happy New Year to all!!
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Sabtu, 24 September 2016

FInishing Up the Big Table

I dont have time to write a long post, but I did promise a potential client I would put up some photos of the table weve been working on ... Also, we picked up the chairs Monday and they are pretty sharp too ... Its our first experience with Danish Cord seats. Nice job by Sandy Sherman Chair Caning of Brookline, Vermont.
This is the second coat of gloss finish .. the final satin coat will go on probably today
The eight side chairs
Close up ... all for now
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