Custom CNC Floor Inlay

We've got several custom cnc projects going in the shop at the moment. We're making parts for a run of custom directors chairs for another furnituremaker, prototyping some screen panels for a Connecticut designer and making two custom deck inlays for a boat in Milwaukee. The Milwaukee client had a problem with his fuel tank and had to cut a pair of holes in his teak deck. He sent us a drawing and two round teak blanks. We translated the drawing into CNC router language and after cutting the recesses, we're in the process of fitting the individual inlay parts into the 12" diameter pieces of teak that he sent us. We'll be gluing the inlays tomorrow and will probably be sending them out to him Saturday. 4/4/08 Sent them out last Saturday .... click to enlarge...

One of the finished inlays

The client's original drawing

Fitting the inlay piece into a test pocket cut in mdf

Trevor, our cnc programmer / operator, 'pointing up' the round corners left by the router bit

The first inlay ready to glue

Bubinga Entry Console

Along with the metal bench below and two other side tables, we are working on a bubinga console table table inspired by an Art Deco design from the 40s, by Pierre Lardin. We have changed the brass details a bit, changed the height and simplified the legs, but mostly, it's pretty similar. It has a really nice feel and will look quite elegant across the room from the bench in the post below. The curved aprons were laminated in three steps using a core of 3 layers of 1/8" bending poplar and two layers of 3/8 'Wacky Wood'. We next applied the 1/16" face veneers inside and out, fitted them up and then applied the 3/16th" bubinga applique. We made the top first, cut it to shape and constructed and fitted the base together while the top was upside down on the bench so we could see the shape we were trying to match. We fitted up the curved aprons using temporary poplar aprons to be sure we had our joinery correct before cutting the real bubinga ones. Worked slick.

The table ready to go ...

The side tables in the photo below

We're awaiting our clients return and final input before starting with the finishing. The brass diamond will be antiqued and lightly highlighted like the other brass on the table. Stacked beneath the console are two bubinga side tables with gold abalone faced pulls.

The table after the meeting today. The domed center detail was rejected in favor
of the brass diamond lying on the table. The fir aprons are mockups to
check the shape. We'll add the real bubinga detail now.

Showing the application of the raised apron detail and the core
construction of the apron described above. We used short tenons
because the real structure is derived from having the front and back
aprons connected with square pieces just inside the front legs. Makes
things a lot simpler ...

The brass feet are made from 3/4" square stock with short
square tenons mortised into the bottom of the legs,
drilled and attached to the tapered legs with long screws.
In the photo above the square proud pieces in the finished
brass details have been replaced by masonite for sanding ..

Fitting up the top brass moldings which are colored
chemically and epoxied into grooves in the legs.

The first clamp up with the poplar aprons

Mango Wood Desk

3/9/08 This past week after shipping out the big 'Walnut Slab Table' shown in one of the February posts bleow, we started work on another, smaller, slab top table/desk. This client selected a mango wood plank for the top of the desk from two that I had on hand left over from a previous project. The process pictures below are shown in reverse order through the concept and construction process. This week, after final sanding and prepping, we will restain and finish the wood to the color in the picture of the original planks at the bottom of the post. After arriving in this country from somewhere in Southeast Asia, and in Vermont via New York City, the mango wood and steel desk will, as of the 24th, be overlooking the harbor from an office window in downtown Boston. Click on the photos to enlarge.

When this project was finished, the client sent me the nicest email, which I have copied and pasted below ...

"Dan – just a quick note to say THANK YOU for the beautiful job you and your team did on my desk. Every day I get at least half a dozen compliments on it. It truly is a work of art. Thank you for your creative vision, craftsmanship and attention to detail. I will cherish this desk while I’m here, and if I leave, it’s coming with me!

Lesley Bielby
Chief Strategy Officer

The information contained in this message and any attachment may be proprietary, confidential, and privileged or subject to the work product doctrine and thus protected from disclosure. Any dissemination, distribution or copying of this communication is strictly prohibited. "

3/17/08





All in .. all done ... ships out Tuesday for Boston .....


With the steel in place and the live edges on the base

the plank repairs completed

After rough planing and flattening, some bark pockets and cracks appeared under the finish that was applied to planks in Southeast asia. This often happens and the necessary repairs add to the interest in the final piece. It's often impossible to anticipate what you may have to deal with when using lumber like this, but that's part of the excitement and interest that comes from using it.

We started by making an mdf mockup of the imagined shapes for the base before cutting the planks to final length and size.

Mocking up the steel and determining its final position.

The original inspiration piece from my website , 'Wood and Metal' section
http://www.dorsetcustomfurniture.com/ItemDetails.aspx?iId=264&mId=-7&pcId=

The two planks ... the client selected the one on the left for the desk top
and we used the other for the base. We originally left the live edges on the base supports, but after some consideration, we used the curve of the steel to assymetrically shape the verticals to give the piece a less rustic look. The curved 3/4 " solid steel was fabricated in our custom metal shop.

The Williams Store Railings

Double click the pictures for better viewing

Well, the HN Williams Store expansion project is now open to the public! Sam has spent quite a bit of time on these railings, starting last fall. The items welded into the tops of each section came from the attic of the store. Williams Store has been in the same family since about 1840 and some of the stuff they found when cleaning the attic is definitely from the early days. Read on their website about the time when the horse bits and the shoe forms in the one section of the railing were part of the main business of the store. They recently redid the foundation of the whole store and created a new lower level for hardware, garden and yard tools, and clothing sales .... and, hence the railings ... Contact Sam at 802 867 0139 for custom metal railings, forged, welded or fabricated metal objects, fireplace tools, metal repairs, or to order a piece of wood and metal furniture from the 'wood and metal' section of our website. In the post below about the Walnut Slab Table you can also see Sam's handiwork on the metal parts of the base.


Manure spreader gears, elevator chain and tractor bucket teeth...

A maple syrup draw off valve....

One of the five horse bits, more manure spreader gears
and some cutter bar teeth...

A Round Expanding Table

4/7/08 ... We finished this one up a few weeks ago but it's not leaving for a minute and I just got around to taking the pictures and adjusting the photo images. Great project. As usual, more complicated and more pieces than I thought, but a still a great project, nonetheless ..... Click to view ... Story below ...



The finished table in the closed position


With the four 18" leaves

Underview showing the concealed leg and the runners ...

2/22/08 We started the design work for this project back around Thanksgiving and we're now well on the way to wrappng it up. It will sit in the formal parlor of a fine, vintage 1840's, Philadelphia townhouse. The photos are posted from conceptual work through the present in reverse order with the most recent at the top. Double click the photos for better viewing. The table is built using figured mahogany and will have black painted details and ebony and burl inlays. It will be a 39" round in the closed position and will open to 112" to seat 10-12 comfortably.

3/15/08
We were about to apply the final coats of finish to the table top when I realized I HAD FORGOTTEN THE ABALONE TRIANGLE INLAYS !! It was kind of nerve wracking inlaying them into the nearly finished top, but they came out fine and are definitely a nice, eye catching addition to the overall design ...

INlaying the triangles process....

Outline

Rough rout with 1/16th" bit

photos above show the marking, routing and hand fitting inlay process

3/9/08 ... Close up of the top with the completed edge inlay, ready for final stain on the mahogany.

In this picture, the pieces have been firstcoated with stain and the inlays have been masked off in preparation for the final color on the mahogany. You can see the finish sample of the final color in the foreground and the black apron details nested within the leaves. the other black column details and moldings are in thefar background. All of a sudden it dawns on me that there are A LOT of pieces in this table.

Inlaying the edge detail.

Showing the length of each piece of edge inlay.

2/27/08 We're now working on the burl center inlay for the main table and for the leaves. The small half circles we can glue to the table with clamps , but the leaves will go in a vacuum bag press so the the larger area (11 x 18) can be clamped with more consistent pressure.

Fitting up the pie shaped pieces of the center inlay.

Clamping the fitted inlay to the table.

Fitting up the inlay for the leaves 2/27

The table as it is today 2/22 with a photoshopped on apron and painted molding detail

My son Will, rough bending the inlay pieces for the circlular ebony inlays with a shop made 'hot pipe'. He could, with just the hot pipe and careful control of the heat, bend the kiln dried ebony, or most any other thin wood, into a radius slightly larger than the pipe itself. We learned this technique from the guitar makers catalog, how to books, and a little experimenting. The .35" burl line is cut, not bent.

A close up of the inlay process. This is actually the third step, as each layer is glued in, one piece at a time, using the nails to temporarily force the pieces into place until the glue dries. The blocks for the edge inlay are in the backgroound.

End view of the whole table with the triple outer inlay border (ebony/burl/ebony) set.

The table in the open position, without its center leg

The split pedestal with its center leg and shop fabricated column locking mechanism

Gluing up the tapered column

Checking the column piece cutting jig with an mdf mockup

Sketches of possible inlay designs...First table, top left is the one we're building.

The parlor with the proposed table photoshopped in

The parlor patiently awaiting its table