Category Archives: Cabinet Projects

I Madonnari 2017

The 2017 featured artist at the base of the mission steps.

The 2017 I Madonnari Italian Street Painting Festival was held this past weekend. I was a participating artist in twenty-five of these events, but between knee and shoulder replacements I have retired…or transitioned to being part of the all-important audience. Camera in hand, I joined hundreds of others at the Santa Barbara Mission mid-day Saturday to catch the early stages of this marvelous event.

The Mission Santa Barbara, home of the I Madonnari Italian Street Painting Festival.

My Aunt Sandi was in town for the first two days. Fun to share this tradition with her. The images below were taken Saturday and Sunday of this three-day festival. There will be another post of images taken early Monday evening when the artists had completed their magic. This festival has been held for thirty-one years. Make your plans to join us next year over the Memorial Day weekend

Penny Collector Frame, finished

The Penny Collector poster nestled into its new home.

The Penny Collector poster is ready for hanging in my office. I carved a simple Buhl-diamond on the backside of the top rail with V-gouge. Then finished with multiple, thin coats of Tru-Oil finish. I may take the sheen down a bit after it is fully cured with light 0000 steel wool buffing  or I may leave it as is. Time will tell. I found out about Tru-Oil from the BenchCrafted blog [http://benchcrafted.blogspot.com/2015/01/why-you-should-be-using-tru-oil.html]. Jameel’s blog and BenchCrafted are at the top of my list for insights and inspiration.

Cherry plywood for backer

I wanted to make the backer from material on hand. Made one using left-over teak plywood. Liked the look (not that it will matter facing the wall), but the board had severe cup which would stress the hardware holding it in place. Oh, btw, I used two figure-eight connectors for that task.

Next I dug out some cherry plywood left over from one earliest projects (before I swore off plywood). The figure is not particularly pleasing, but it will amuse the spiders as they spin their webs in the dark.

The glass was cut to size (12 x 18) at my local glass shop and placed along with the poster and backer into position. Then it was photo time.

If you missed part one of this short series, this letterpress poster was from Carrie Elkin [http://carrieelkin.com] as part of her Kickstarter campaign for THE PENNY COLLECTOR.

Penny Collector Frame, p2 – Glue up and repairs

Epoxy time

We left the last post with a destroyed lower rail. Before attempting a patch, I felt it necessary to stabilize that rail from the back side. Flowed lots of West Systems epoxy into the rotted areas, but did not attempt to level the surface. Once cured I sanded any epoxy above the rail’s plane.

Drawing rail shapes

I drew a curve for the upper rail as well as angled ends of each rail then blended those with rounded corners. Cut the angles and curves at the bandsaw and cleaned up with rasps and sanding. I also drilled a shallow hole which will have a shiny penny placed once everything is complete. 

Dry fit test. Shows hole for penny and the destruction to the right side of the lower rail.

Here you can see the consequence of the destruction. My material supply was pretty limited but I found a piece to create a full-width patch. After gluing the frame I routed a shallow rabbet to capture the patch. When gluing the patch in place I did not notice it had slipped away from the cavity. I used liquid hide glue so was able to apply water and prying to remove the patch.

Patch number two

However, the fragile patch did not survive. Next I made a patch of two separate pieces which matched each other pretty well, though not as well at the ledge as my first attempt. Glued those into place while paying better attention this time. The patch was sanded level with the ledge of original material and edges cleaned up. 

After a final sanding it was time to begin finishing. Jameel of BenchCrafted had blogged of Tru-Oil a while back. I tried it for one of my Esherick-style music stands and liked the look. No sure I would do a large piece that way. But this would be a good opportunity give it another look. 

Next up: Putting it all together

Penny Collector Frame

A 1-3/4 inch thick hunk of chestnut being trimmed to “straighten” the grain lines.

A picture/poster frame can be a nice one-day or weekend project. Four sticks of wood with a bit of joinery. No big deal. Or, you can work like me and enjoy weeks of fun and lessons learned the hard way. 

For my support of Austin-based singer/songwriter Carrie Elkin’s Kickstarter campaign I received some fun swag. In addition to her touch-your-soul music, there was a 12 x 18 letterpress poster which deserves a nice frame. Check out THE PENNY COLLECTOR if you are interested (hint: you should be).

Parts milled (jointed and planed) four-square but a bit over-sized. This allowed me to decide on widths of each element.

For this project I used the last remains of the large Chestnut slab I bought from a Maryland hardwood dealer several years ago. This would be tricky with some rotted areas to contend with. I selected half-blind dovetail or maybe it should be called dovetailed ship-lapped for the joinery. The stiles were identical while the top and bottom rails would each have different thicknesses and widths. The stiles came in at ~1/2 inch thick, top rail ~3/4 inch and the bottom ~5/8 inch.

The four sticks were rough cut from the slab at the band saw, then one face and one edge made true at the jointer. Power planing took the pieces to final thickness. All sticks were over-sized at this point. Rabbets were routed to receive the glass, poster and backer. Stiles were through cuts and the rails stopped, then squared with chisel.

Dovetails cut on stiles. A small ledge was created on the upper face to create a shoulder.

Dovetails were marked at each end of the stiles. Shoulders yield 18 inches between the upper and lower rail rabbets and 12 inches between the stile rabbets. A 1/32 inch ledge was created at the router table, then the dovetails cut at the band saw. Final clean up with chisel to create clean shoulders. In the photo you can see the consequence of making through rabbets. The tail is flush to the socket so should be fine. However, that small triangular area is fragile and broke off on two of the joints. Not a big deal as the contact at intersection is intact. However, as I was cutting these (and the sockets) freehand I did not need to keep them to standard shape. Small lesson learned (more serious lessons to follow).

Ready to begin chisel paring to the knife lines. What you do not see in this image, but can tell if you are familiar with the Roubo wagon vise, is the cavity underneath where I am about to cut with the chisel. Yes, I cut right through to the face with major blow out.

Sockets were first cut with a trim router and straight bit. I stayed away from the knife lines. The router makes a nice flat reference depth (unless you tip the silly router as you work). The top rail went well and fit nicely with just a bit of chisel finessing. The bottom rail began as a minor problem and then escalated. The underside had considerable rot, which I was aware of. I was not, however, aware of how deep and extensive that rot was. Then the big lesson. After routing the base depth, I began to pare to the knife lines and KAPOW! Chisel went right through the face side. Why, you might ask. Well the rail was directly above a cavity in the workbench. That cavity is for the wagon vise block to move in and out. I saved the two large and one small busted pieces thinking I might be able to repair. Later I will discover the puzzle would not go together.

Next up: Glue up and repair and prayers

Sculpted Walnut Stool – Leg Joinery

Material for the legs

Material was selected for the legs and roughly cut  at the band saw. At this stage I am looking to create reference surfaces for the legs while leaving as much material as possible for future shaping. 

One of the front leg sticks had punky area at the bottom which I hoped would be outside of the finished area. However, my confidence diminished as I pondered the process, so I chose another stick to work with. It had its own issues, but I will not know the outcome until further along the process.

Hand plane a flat and perpendicular edge for joinery

I jointed the rear legs enough to have reference faces, then used a hand plane to create a flat and perpendicular area for the joinery. Dadoes were cut on the table saw to fit notches at the rear of S3.  When a tight fit was achieved, a round over was cut at the router table. The round over and dadoes match the notches and rabbets on S3.

Dry assembly (sans back support)

Front legs were similarly created other than this joint is less secure, being  only captured on two sides (rather than three on the rear legs). Cutting those dadoes and round overs only required one good corner. After test fitting, the entire stool was dry assembled for a photo op. Not so elegant at this stage, but the foundation has been laid.

Sculpted Walnut Stool – Seat Joinery

I cut the bevels the opposite of my intentions and the clear chalk marks. How does that happen? Life mysteries.

S3 and outer edge of S2 and S4 receive bevels to roughly create a deep saddle. Like any prudent craftsperson, I marked the bevel orientation with highly visible chalk marks and then proceeded to ignore those markets. Cutting the bevels opposite my intended orientation. A solution was to flip the underside to the topside. Besides the grain being different than I had chosen, the new top side has a large funky area that I had determined would be a non-issue on the underside. Hopefully, it does not go deeper than my planned sculpting. This is not the first time I’ve messed up bevels. I guess bevels at the table saw befuddle my brain.

Notches for leg joinery cut at rear of S3 with dado stack

S2 and S4 also receive the bevels on the outer edges. Those went as planned. Notches for the saddle joints at the rear of S3 and forward, outer corners of S1 and S5 were cut with the dado stack. The S3 notches required holding the workpiece vertical, however the generous flat combined with thick stock made this feel secure enough for my standards. The dado stack was set up for 3/8-inch bites so I nibbled to the layout lines.

After the notches were cut I used a rabbeting bit at the router table to create shoulders matching leg dimensions. The seat segments were oriented and marked for floating tenons. Those tenons are made from 3/8 x 1 x 2 inches Baltic Birch plywood. [Note: 3/8-inch plywood is less than 3/8 inch thick, so I used 1/2-inch thick ply and reduced to 3/8 inches using the power planer.] 

Mortises for floating tenons on seat segments

Mortises were cut with a 3/8-inch spiral uncut bit. A jig would be appropriate, but I chose to balance the router on the workpieces as best I could. Those on perpendicular edges were captured flush on the Moxon vise for solid support. The bevel edges were trickier. I did the first ones using the end vise and battens. Subsequent ones were placed proud in the Moxon which felt more secure and at a better work height for the task. The mortises were squared up with a chisel and the seat dry assembled with floating tenons and a rough shape was drawn with black marker.

Next up are the legs.

Sculpted Walnut Stool – Beginnings

Walnut slab broken down for easier hauling and handling

In 2013 I built a sculpted stool based on Charles Brock’s Bow Tie plans. It has received many positive comments over the years. Now I am revisiting that project as a gift for a friend. I found a large slab of walnut at Santa Barbara’s LocalWood.net. Rob Bjorklund operates this business high in the Santa Ynez foothills along the old pass road. You may wish to use the link to learn more about his operation.

I was able to find the components in the longer/narrower sub-slab. The many artifacts including extensive worm holes may cause me to change the selections as I cut into the material. We shall see. Worm holes can be small on the surface and lead to major cavities as you dig further.

Stool with lumbar support, 2013

This “simple” stool [photo on left is the first version] consists of four legs, a seat and a back rest. Easy. But the joinery is more complex than traditional mortise and tenons or dovetails. Then the fun part is sculpting. I will finally be able to use my Claire Minihan travisher that has patiently awaited its first serious mission.

I marked the components then used a jig saw for rough cuts. When possible they are well over-sized to allow adjustments. These elements were further cleaned up at the band saw. 

First up is the seat consisting of five elements. One face and one edge were jointed. The center seat section (S3) was too wide for my six-inch jointer so I jointed it with some overhang. That proud material was brought to jointed face level with hand plane. A power planer let me create flat reference faces and the table saw used to rip the opposing edges. To save material I did not make the faces perfect, just clean enough to work on the joinery. There is no need for super clean surfaces with all the shaping to follow.

After this milling I restaged the seat components and identified orientations for subsequent steps.

Small table, p3 – Ready to deliver

The table is completed other than glue up. I will be doing the final glue up when I visit Michigan this summer. The legs and stretchers are from a different log than the top. The top is quite dark, with marvelous figure. The missing chunk on the underside and edge will be a conversation starter for many, many years.

I was pleased to be able to use the plank remnant for this small table.