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Were working on a distressed walnut table top for a client who has a masonry pedestal. Were just making the top and the apron/stiffener. Its nearly finished and looking pretty good. Click the photos to enlarge them ...

The rough lumber form Irion Lumber in PA ... Beautiful boards, all from the same log.

Glued up and cut to round with a circle cutting jig on the bandsaw.
Heres one way to do it ... circle cutting jig There are simpler ones, like a board and a nail

We like this next process. Its quite fun. You move the pin that you use to cut the table round out away from the blade and one person spins the table (Trevor in this case) and one person (me in this case) holds the belt sander square and level. Once that kicks in, then you actually have to keep the top from spnning too fast. Sanding the cut edge this way takes only a couple of minutes .... Dont skip grits .... Dont let it take off ....

Trevor mortised the six round apron parts with the domino and glued them up in a circle using the band clamp, adding small moldings to the bottom edge to reinforce the glue joints.

View of the table bottom.
More later this week as its completed

The clients pedestal

Last week we drove from CA to OH and to say that Im happy to be somewhat settled would be an understatement! Before we moved, a good bit of time was spent returning our rental to its bland self, selling tons of furniture on craigslist (if youve ever done this you know its very annoying except for meeting a few very sweet people, if youre reading from the central coast, you are one of the exceptions :) clearing out the garage (that took way too much time and too many trips to the dump/habitat restore), and de-junkifying ... Im exhausted just thinking about the few months prior!

Over the weekend David named this MEGA PROJECT, and for good reason, we were basically a lumber mill without the correct equipment. It was A LOT of cutting! Well go into that more when we post a tutorial ... but for now, check out our progress!


Rough pieces of driftwood were cut down to 1x4 pieces of wood to give a variety of color and texture. LOVE!




Weve finished everything but two edges, then well be almost done with the top!


Youve probably guessed by now, but it is going to be a coffee table for our living room ... check back for progress!

The finished book stand.

I begin with an apology. Im sorry for not having posted since October 22. I try to post at least weekly. A number of personal and work projects have conspired against me lately to prevent my posting. Chief among them was the Sawdust Chronicles 2010 Build Challenge.

As I was entered in the Build Challenge, Ive spent every free moment over the last few weeks working on the book stand which I submitted as my entry. When I lost my build time on the final Friday and Saturday of the challenge I feared it may have all been for naught if I failed to complete my project. Thankfully Rick was nice enough to extend the deadline for all and I successfully submitted my project almost 4 hours before the it was due!

Here for you, my dear readers, is part I of my submission description.


As my entry to the Sawdust Chronicles 2010 build challenge I have constructed a book stand. The book stand is constructed from walnut and glass tile, assembled using Domino joinery and finished with 6 coats of de-waxed shellac.

Design Process
When I decided to enter the Sawdust Chronicles 2010 build challenge in late August I had already been asked by my mother (a second grade teacher) to make a book stand for the dictionary in her classroom. She had given me a print out of some book stand designs, a physical copy of the dictionary to be held on the stand and a request of a 60 degree display angle. On review of the Sawdust Chronicles 2010 build challenge rules and entry form I quickly abandoned the designs she had suggested and got to work on my own.

The Bell Forrest project pack & the glass tile laid out on my table saw.

My starting point was walnut. I had always wanted to work it and when I saw Bell Forrest Products labor day sale I ordered a 10 board feet project pack and hoped that would be enough (it ended up being almost twice what I needed). Another point I wanted to incorporate from the beginning was a secondary material. My initial though was copper, as I have experience working with sheet metal at work, and copper is such a beautiful metal and so easy to work with. My idea was to use copper sheet metal to veneer a piece of MDF which would act as the arm portion of the stand. Unfortunately, the build challenge rules forbid the use of MDF, so I began to track down some plywood to veneer with the copper. During this early stage of the design I was walking through Home Depot and was inspired by the glass tile on display. I bought some there on the spot and decided that rather than use copper to veneer the arm portion of the stand, I would use the glass tile as an inlay for the center section of the top where the spine of the dictionary rests.

The tile laid in position during a dry fit.

Incorporating the tile into the design was the inspiration for the top. I recessed the center tile section for the practical purposes of housing the tile and holding the dictionary spine and for the aesthetic purpose of allowing the side sections of the top to rise up and away from the center like wings. After some trial and error with the actual dictionary, I decided on 10 degrees as the appropriate angle for the wings. Once I had the top designed, I set to work constructing it. I had finished assembling the top before giving the base design any serious thought. Since I knew the top had to be held at a 60 degree angle, I started with that and cut the now walnut support arm at 60 degrees. I ripped it to width so that it matched the top. The base was the final component I designed. I made it slightly longer than the support arm to give it small lips in the front and rear. I determined the width of the base though a combination of what looked good to my eye and what was wide enough to support the top. In order to give the piece visual balance, I gave the bottom wings angled down at 10 degrees to mirror the angle of the upper wings.

More on the build in the next post. Until then check out my 2010 Build Challenge Photo Album.

What did you build this fall?

Actually, the claro walnut table above is not quite done, but we did put a polishing coat over the final brush coat of finish today when we got back to the shop. That one will be finished up by the weekend. Will and I were in Grafton most of the day finishing up the This Old House project that we have been working on off and on for over a year. We had two missions today: the first was a small adjustment to the big tv cabinet to get one pair of the folding doors sliding smoothly into the cabinet when it was open. When we left it a month or two ago, it was on a couple of furniture pads and the tv and audio equipment had not yet been installed. Happily, all the stuff fit in nicely and the door adjustment went smoothly. We got a demo from the owner of a short segment of the Roy Orbison Black and White video and the surround sound really rocked !!!! It was close to feeling like a live performance .... The TV was not too shabby either ... Click the photos to enlarge them .
Figured cherry, curly maple panels and walnut moldings ... Getting started info on the construction of this cabinet at the link above ...
Looks good closed too ... another post on the construction of this cabinet here
The other cabinet in the family room was fine and the tunnel we created for the cable box installation worked slick .... This cabinet needed no adjustment ...
Post on this cabinet here ...
Our main mission today though was to install the shutters above in the family room across from the cabinet above. This project was a little nerve racking because it was added at the last minute and we had to construct and finish the shutters in the shop without checking them in the opening before we finished them ... Will was relieved when they fit like a pair of gloves and even complimented me on my hinge layout jig, which I forgot to take a picture of and did work slickly...
Pretty dark in here with the shutters closed ...
The lights were on in the fireplace cabinet (scroll down), and it had a nice glow ...
And the front door, which Im pretty sure is the original, looked happy to be back in place ...
Tthe cabinet we wrestled into place the last trip was full of stuff and looking like it was designed to be there from the start, which it wasnt ... Over all, its a great felling when you finish a large project with a client you have particularly enjoyed working with for an extended period of time .. I hope hes not completely finished though the house looks good, and Im sure hes ready for at least a deep breath ...
We even had time to stop for a late lunch at The Wood Fired Pizza Company where Peter Moore built the oven and Sam made the doors ... Yum ... All for now ....