Friday
Dec242010

Potting Room of Reclaimed Wood

The beams were taken from a hand hewned log cabin on the customers proprety. We had them sawn by a local sawmill on three sides and beveled the edges for re-assembly so they were hollow and much lighter. We were able to install them as "U" shapes on pre installed blocking.
Reclaimed siding from one of their barns was used in the cabinet and walls.
The hutch is a combination of scrub planed and weathered chestnut from their barn. The biggest challenge was to protect the original patina of the siding during construction. Note the hand turned "bun" feet.
The casing is resawn ceder from trees cut on the property. Our new resaw came in handy for this.

 

Thursday
Dec232010

Flat Screen TV Furniture Design

We've been playing around with a design for a flat screen TV cabinet. It would feature curved laminations with veneers of contrasting colored woods (we're thinking maybe mahogany and birdseye maple) and a very special door that raises and lowers with a hidden mechanism.  All wiring would be behind the vertical back panel.

This design needs a home.  Could it be yours?

Thursday
Dec232010

Walnut cobblers bench

 

 This cobbler’s bench is a copy of one that was found in my great-great-grandfather’s barn in New Point Missouri. Like the original, it’s made entirely by hand of black walnut (the original used the same walnut that the barn was built from).

Thursday
Dec232010

Maple "clouds" lighting fixtures

These light fixtures are made of two layers of 3/8” bendable plywood sandwiched by two layers of 1/8” Italian bendable plywood. Then they were edge banded and veneered with maple. Usually we would do the lamination with the piece and form inside the bag but due to the size (9’ x 4’) we decided to try it with the form outside the bag. It worked fine, as you can see.

We then leveled any imperfections before veneering. Once the veneer was applied and sanded, the holes were located and cut for the lighting.

Staining wouldn’t have been my first choice, but the customer wanted it. The pieces were stained and finished with satin pre-cat lacquer.

We designed the hanging hardware, which were ball-joint rod ends on custom made clamps. The fixture hung on threaded rod which we located in the ceiling before we started fabrication, so the sheetrock and wiring could be completed. The day of installation, the rods were covered with black painted conduit. Installation of the lighting was done after the units were hung. This is the kind of work we love to do, different and unusual.

Monday
Feb092009

Black Walnut Hand Railing

 


This was a challenge. Two staircases, four floors  (8 runs) of railings. The contractor called us less than a month before the customer was due to move in. The rail had to encase a 1/2" x 1" bronze channel that was supposed to be done before we got there. It wasn't. The iron guy was new at it and we made him redo about 80% of it due to uneven curves or it being out of level.   If the ironwork isn't level the railing profile will be distorted.

There are no easements or newel posts so the railing had to be continuous from top to bottom. The joints were to be smooth. The idea was to be able to put your hand on the railing at the top and never let go until you get to the bottom, while never feeling joints on the way down. All of the joints were done with  5/16" rail bolts. We had a bandsaw, several routers, router jigs, custom router bits and lots of hand tools on site. We worked for about 21 days to finish on time. These pictures are with the railing having only one sealer coat. If you've seen our post about making curved handrailing you'll know that Mike spent many days just fitting the blanks onto the bronze channel before we were able to do any shaping.