well, in my previous post i mentioned that we had TWO
challenging projects ... here's the second one ..
click the pictures to enlarge them
a few inlays, some nice mahogany, a natural finish,
what's the big deal?
like a lot of things, if you do it right, it all looks easy.
ever watch a good golfer? try that and see how you do ..
so, we had some info from a designer that determined
the basic inlay layout and colors
it was relatively easy to import that image into our cad program
and draw over it, keeping as faithful to it as we could ...
but then we had to make the wood look like that, and
have all 50 little leaves fit precisely into all 50 little pockets
that Kristian cut for them on the cnc. we first tried cutting
them and sticking them in the pockets, sanding them flush,
then taking them back out and painting them, woodburning
the veins into the leaves and gluing them back in ...
this is the general idea, in walnut. originally it was
going to be a redwood piece, but at $42. a board foot plus shipping
and not easily accessible in the rough, we tried walnut and
in the end settled on some old, wide, short,
6/4 x 3' mahogany boards i had on hand ..
tedious for sure, and tough to glue them in perfectly flush.
the paint could not be sanded even a little bit or the
wood showed through. will suggested that we try some of
the pressure dyed colored veneers he uses for his
banjo inlays ... BINGO!
these veneers were a little over a 32nd thick and kristian
epoxied them to some 1/16th inch poplar, cut them to fit,
sanded them flush and made some test panels from mdf.
the branches are made up of multiple pieces of natural walnut
joined in the obvious places ... lots of pieces there too!
there was a thought that we could add some 'falling leaves'
to the third door, but they didn't seem to fly.
and did i mention the refrigerator?
all kinds of complications there ...
the door rises as it opens and the door can only be so thick
or it binds on the case before it gets to 90 degrees.
'do not obstruct the vent in any way' said the
instructions ... but it's ugly
and there's a switch that turns the light on when
you open the door. we compromised by making
some slots, cutting the switch thing shorter and using
magnets to allow the base piece to be removable as needed.
anyway after some trial and error and some serious back and
forth emailing and sample mailing, we were able to
wrap it up last week. we are waiting for our shipper
to grab it and deliver it to asheville ...
hats off to kristian for pulling this one off !!!!
it was not as easy as it looks!