Wednesday
Nov122008

Desk of Aromatic Red Cedar, Walnut and Poplar

This desk was made to fit against a window wall in a hexagonal home office. Mike drew this desk in AutoCAD, so we were able to make a template of the top including the position of each leg in relation to the skirt. This allowed us to lay out all of the joinery, in place, on the template, eliminating errors that might happen if done another way.

The skirt of the desk was done as vacuum laminations of two 1/8” layers of cedar onto a core of solid heart  poplar. 3/4” was ripped off the top edge of the skirt and the drawer fronts were cut from the remaining. Then the 3/4" ripping was re glued to it’s mating piece. In that way we were able to keep the grain continuous and the gaps at the sides of the drawer fronts tighter.

The legs were joined to the skirts using hand cut mortise and tenon joinery. The drawers are of course, hand dovetailed.

The top is 2” thick black walnut cut from the owner's farm. It is two book matched slabs scrub planed with hand eased edges. The two slabs meet at a corner in the wall, at a 75° angle. They are joined with a tongue and groove joint and hanger bolts. The finish is hand rubbed lacquer.

Wednesday
Nov122008

Aromatic Red Cedar and Glass Entry

This contemporary stone home had a unique way of bringing the outside in. Two stone walls turned in towards each other, making a ten foot wide alley.
The idea was to put a wall of glass there to separate the inside from out. Our solution was to build a sub frame of white oak and clad it with aromatic red cedar. The glass is 1/2” insulated , lo UV .
Not sure that the cedar would hold its stability, we decided to make the door and side lite parts in the stave core or engineered stile method. The cores of the parts are of quarter-sawn Spanish cedar, clad with 1/8” aromatic red cedar flitches and 3/4” solid edges.
The unique handles are hexagonal in cross section with an inlaid walnut accent stripe. The handles are mounted on custom-made brass standoffs, with Gaboon ebony plugs to hide the set screws.

Wednesday
Nov122008

Wall Unit of American Black Walnut

This 18 foot wide by 8 foot tall unit constructed of American black walnut solid and veneer, has a 1-1/2” solid slab top with a natural edge.

An interesting element of this piece is that it sits a half inch off the floor and a half inch from the ceiling. These void areas are air intake and returns. Hidden in the center soffit are two 6” flex ducted fans that draw air from the heated floor and exhaust it at the ceiling. There are also two 2” ducts that draw heat from the center TV cabinet. The lock mitered columns enclose the ductwork.

The curved upper doors and their laminated walnut and cherry track are on a 511” radius to follow the natural edge of the top. The track is suspended from column to column with no other support.

The cherry trolley wheels were cut on a CNC router with grooves cut by hand on a lathe. The wheels rotate on ball bearing hubs.

This unit was pre finished with conversion varnish.

Tuesday
Nov112008

Rustic Railings of Found Aromatic Red Cedar and Vines

We love being able to do new things, so when the customer told us she needed railings for her patio we jumped at the chance.

The newels and main railings are of aromatic red cedar found in the woods around the house. Care was taken to find just the right curves and sizes. We spent a weekend walking the property with marking tape and a chainsaw picking out likely candidates. With a pile of what looked like the start of a good bonfire we began selecting our posts. The posts are set on 2” galvanized pipe core drilled into the sub stair. They were later embedded in 8” of concrete and stone. We got to use some cool tenon cutters and our 1/2” hole hog drill to do the joinery and added a wedge just for fun. The vine work was grape and Osage orange. It was wired and nailed with hand cut clinch nails to the structure. No finish required.

Wednesday
Oct292008

Spiral Handrailing

Also in this house are about seventy feet of straight handrailing, and the handrailing for a spiral staircase. You can see construction details on this particular spiral staircase in the "How We Do It" section. The spiral was handcarved, as were the railing ends. There are also a few locations where the spindles go through the handrailing. These details required a lot of specialty hand work. Also note that the spiral changes directions at the top.