Showing posts with label Handforged Hardware. Show all posts
Showing posts with label Handforged Hardware. Show all posts

Sunday, October 18, 2009

Update on the 'This Old House' Project


We're working away pretty steadily on the house restoration project . We finished construction of the wall hung tv cabinet this week; we're just waiting for approval of the finish color samples. I think we're running slightly ahead of the construction schedule which is always nice. The cabinet below has it's challenges though it looks simple now that it's done. It's a mix of cherry and curly maple with some small moldings in cherry or walnut around the door panels. The door and end panels are resawn solid curly maple so we like to do the first coat of stain (which is pretty much always the same) before we glue them up. Then we typically get the finished color and first coat of finish on the whole door before we apply the moldings. This process prevents a part of the panel that might be unfinished from showing later as the wood moves from season to season ...

Looks simple ... but, there's actually no real much structure to the cabinet so we had to hang it as it's going to hang on the wall to be sure that the doors will hang true.

When we went to the site this week, we took a pattern. There is a channel cut through to the wall behind the cabinet to accomodate the cable box, which is deeper than the cabinet .. We explored the wall behind and found there are two studs that have to be cut and headed off ... not surre about the ebox shown below ... I'd like to get that in there somewhere ..

This shows the cut through to the wall and the tv mounting bracket. It a Sanus; a nice one. Very shallow and well made

This picture shows the French hook hanging system ... Two cleats on the cabinet; two on the wall.

The electrician gave us this box on Wednesday and hoped we could get it in the cabinet behind to the tv ... hmmmmm

We finished installing the moldings and painted the front door .. The paint seemed too shiny for an old door to us. The shinier the finish, the better the UV protection, but the more you see each and every pimple and defect ... We turned the final coat over to the painters and it will probably be a compromise satin finish ...

Part of our scope of work is to refresh/refinish the fireplace surround (which Jim has already done), and install a new lighted cabinet in place of the wooodbox/shelf thing that's there now ...

Trevor, exploring the lighting

Figured out .. This stuff is nice. The plastic tracks are easy to install and hold the lights securely. It's easy to cut and join once you study it for a minute ..

Rough wired and installed ..needs a top molding and some final paint

We also made a pair of 3" thick, well insulated, pine doors for the utility room. Sam made the hinges, floor bolts and a nice thumb latch ...

Inside latch details

Fixed door bolts

2" thick pine frames covered with 3/4" t&g pine outside, the spaces filled with 2" foam and 1/4" Baltic bircg glued and screwed to the inside

We also installed a small cabinet in the library under the stairs that go to the attic ...

Saturday, April 26, 2008

Greene & Greene Style Sideboard Construction Details

I'm a member of a Yahoo Newsgroup, fans of the work of the architects Charles and Henry Greene. Two of the recent posts were requests for information regarding construction of a sideboard similar to one I am currently working on. For more information on that project scroll down to the post below. The first request was regarding the details of the post and panel ends of the sideboard and the second was regarding the fabrication of Greene & Greene style drawer pulls. In the pictures and drawings below, you can find relatively detailed information regarding both processes. Click the pictures to enlarge ... The exquisite figured cherry, all from the same log is from Irion Lumber in Wellsboro, PA ... 200 board foot minimum, but shipped right to your door ... Ask for Myron .... Tell him Dan sent you ....


Leaving for Greenwich Tuesday AM 5/6/08

Close up of the shop made hinges and pulls
Making the hinges ...

My son Sam made the hinges by cutting down some 2 x 2 blank hinges that we bought from SSS Steel Supply and welding on the shaped long leaves. He then heated them in the gas forge and chased the detail line around the outside edges while they were hot. We then heated and finished them with a linseed oil and beeswax coating, and lastly, created the 1/8" offset by bending the long leaf cold to acommodate the stepping face frame, one of our signature construction details.

Hinges in the gas forge prior to finishing

Cold bending the 1/8" offset.
Clamp is tightened to offset the long leaf on a 45 degree angle.

Waiting for the hardware ... Pulls are done .. hinges will be finished very soon ...


CAD elevation of the the front and end of the cabinet

Detail of the layout for rabbeting and mortising legs of the cabinet

Detail of the end post and panel joinery

Top view showing end panel attachment to case after gluing up
The front frame is glued to the case first
Drawer Pulls

Side view of the pulls installed

Elevation, plan view and back side of the pulls .. 4/19/2012 ... i see this post has made it to the otp of my 'most popular' list ... i am adding a link here to a blog post i wrote shortly after this one that more thoroughly explains the steps to make these pulls ...

The sketch above shows the production process using a router table and curved fence. For safety, we tend to start with wider stock (6-8") and rip off a pull at a time and then the pulls are all from the same piece of wood. If you need more detailed instructions, email me, as I have written out very detailed instructions for my employees.

May 8th After several requests for the details, they are now in a post above dated May 6th .....