Mahogany table & chairs

[Ajcoholic]

So I got a really cool contract from an existing customer... a large mahogany table (slab top, 10' by 48", full 1 3/4" thick) with 4 large shaped legs.

The legs will be 6" square, made up from 4 faces of 1 3/4" thick by 6" which will be mitred and glued up.

I started machining the 16 pcs for the legs today. After machining the blanks - I roughed the profile out with a 1/2" carbide spiral. The finishing passes are done with my 5/8" ball end spiral.

Roughing passes took 12 minutes each. Finishing passes just over 1/2 hour but I am stepping over just 30 thou per pass and it leaves a surface that will require minimal sanding.

Hope to get most of the finishing passes done tomorrow and hopefully get the legs glued up by the week's end.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1771_zpsf5f9370a.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1771_zpsf5f9370a.jpg.html)

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[Ajcoholic]

The chairs will be shaped, in the "Maloof" style. Working off of this photo...


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I will be starting them as soon as I get the kitchen I am trying to finish up out of the shop...

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[khalid]

I always enjoy the work you post. Simply amazing and outstanding.

[scottp55]

Andrew, You got some some beautiful VG and rift Mahogany! Looking forward to seeing your progress. I love the "sweep" of the rear leg to arms on the chairs! What's happening with your rocker? Or are you so close you're going to do a "Voila!" picture:) You planning to do more of the dining chairs on the 'Bot seeing as the dining chairs aren't "one ofs"? Interested in the probing process and learning curve. You just put the pics of your Incras in there to make us feel better:)

[Ajcoholic]

Sorry for posting the photo twice... But I can't edit it out.

The rocker is on hold for a few days. I'm madly trying to get a kitchen done ( mainly get the doors finished and ready for spraying, and the rest of the finishing work done).

I need a day to sand. Just havnt had the time since the last update. I also have another bedroom set to get started on before the customer gets upset. Supposed to be on that one months ago.

I'll get back to the rocker soon.

[Ajcoholic]

I use those clamps all the time. Yes I've cut into them more than once.... Good thing aluminum is softer than carbide!

[dlcw]

Very nice Andrew. I love your work. :)

I will be delivering a 10' x 4' x 2" breadboard end, rustic hickory table on Friday. It is huge and HEAVY.

Get some help in the shop Andrew so you don't throw your back out. :eek:

[Ajcoholic]

Very nice Andrew. I love your work. :)

I will be delivering a 10' x 4' x 2" breadboard end, rustic hickory table on Friday. It is huge and HEAVY.

Get some help in the shop Andrew so you don't throw your back out. :eek:

Thanks Don! I figured (by weighing an off cut and figuring the volume of the table VS the off cut) the top will weigh in at about 270 to 300 lbs. Will be enough of a handful for two of us, I will probably ask for some help to deliver it to the house. Luckily when we move it to the home, it goes in the front door and one doorway into the large dining area. No stairs!

My father made a white pine top when I was in my late teens - the top was a full three inches thick, 10' by 4 1/2'. I remember it took 4 men (well three men and me) to carry it in, on edge on a sling- two guys on each side. We had to go up about a dozen steps. Probably the heaviest thing (besides the staircases we made) I delivered.

A 10' by 4' one pc table is a large table... no doubt about that!

Today I had the Buddy running steady - I ran 11 of the leg faces/panels. Will finish up tomorrow and star mitering the edges so I can glue them up.

I also jointed and planed the top material to see what it looked like. This is going to be one sweet table...

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1784_zpsba36903c.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1784_zpsba36903c.jpg.html)

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[Simops]

Andrew that's one wicked drum sander you have there.......from memory remember seeing one in Norm Abram's New Yankee Workshop!!

BTW what are you going to use to join the mitred pieces......biscuits / dominoes or just glue itself?

Cheers

[scottp55]

Going to be GORGEOUS! I would have put the Naptha to it 2-3 times already Just to show the grain to perfect strangers, but then I lick opals to show people what it looks like at 60,000G too(what can I say -- light has to go in, before it can go out) :)

[scottp55]

Andrew, Did you get the same tree? Boy, you get good wood. You've got a good eye and supplier. I've turned down wood and opal because it was so "Perfect" I didn't know what it wanted to be. My supplier had me pegged when he said "Oh, You like Crazy Wood"----He always set it aside.:)

[Ajcoholic]

Andrew that's one wicked drum sander you have there.......from memory remember seeing one in Norm Abram's New Yankee Workshop!!

BTW what are you going to use to join the mitred pieces......biscuits / dominoes or just glue itself?

Cheers

The oscillating drum sander (in the pic with the leg pcs on the cart)? Or are you talking about the large sander next to the top planks? If so, that's a 38" X 60" wide belt sander - two drums and a platen - the large belt goes around both drums and the platen (flat plate) sits between them.

I will use Lamello biscuits to join the leg panels. No need for the dominos, in this case biscuits are just to align and hold things from sliding around until I get the clamps on.

I might also just run a 1/8 or 1/4" groove and use a strip of Baltic birch ply as a full length spline. That would make the most sense. But since the legs will be tapered I am not sure I can run them through the saw or shaper to grove them easily.

[Ajcoholic]

Scott, naptha gives me a headache! (seriously, it does :D)

One of the stains I use uses naptha as the main solvent, so it dries very fast. I have a sensitivity to solvents and a lot of scents - get migraines. I will wait until I get to oil it up after its been sanded... I am patient! :)

This mahogany I managed to buy (about 350 fbm) last December privately. It came from a closed down millworking shop. I think it is some older stock - straight as an arrow, all 14 foot long. Very very nice wood. I wish I could have gotten more. I paid 1/2 of wholesale cost to boot!

I need to order some more to complete this job and also replenish some of my stock. I know what I will get today wont be as nice as this stuff.

It will make a gorgeous top when it is finished. I am not sure what the final finish/colour will be. I will probably encourage the customer to go with some Danish oil (maybe natural or one I have with a bit of reddish brown tint) and lacquer. I dont want to stain it as such - but that being said, a little deeper colour in the reddish/medium brown tint would also look great.

[scottp55]

No way you're going to match that stuff. Only use Naptha with garage doors open, but People go OMG in 5 seconds and it's never interfered with a finish or been noticeable in a day. Acetone does headaches for me. As I sit in my Great,Great,Great grandmothers Revere and sons "pineapple" mahogany four poster(Custom box spring circa 1920---mattress was impossible to match) I wish they hadn't semi-glossed it as 180 yrs has had it's share of scratches and it's impossible to match the "pineapples" which are untouched. I think they stained it to make it more uniform, but the sun has faded portions so I can see the "warmth" of the reds. Not much beats Mother Nature. I'd lean towards the red on that if I did anything. Gram skipped a generation to give me the bed(Dad was ticked:) when I turned 18. DEEP reddish chestnut now. Got a California King cherry sleigh bed 25 feet away and never use it.
However!!! The customer is always right! Right?
Maybe take a wicked nice piece of "Scrap" , finished YOUR way, and rest it on the table next time their going to come? "Oh, THAT? I was just trying to bring out the best in THIS wood. You KNOW you can't ever get anymore like this RIGHT?"
Pain it's got to "Meld" with all the other pieces, but "If you can't match it---Celebrate it":)
G--, I Ramble after 20 hours
Going to be beautiful!

[scottp55]

Andrew, Most steel truss supports like in your pic are sized for 25-30' bays and 16-24' height at the eves and by the shape support a big central clear span. How big IS your immaculate workshop anyways?

[Ajcoholic]

Andrew, Most steel truss supports like in your pic are sized for 25-30' bays and 16-24' height at the eves and by the shape support a big central clear span. How big IS your immaculate workshop anyways?

My building is 80 by 75 feet (6000 square feet). I have about 3200 closed off and heated (the part you see). The other half is unheated storage. All my lumber racks and sheet goods storage is there as well as my bobcat, etc.

If I ever need more space I can close in more of the currently unheated side.

The steel buildings ceiling is indeed high. 13 or 14' at the eaves. That's why my inside ceilings are 10'. My ceiling trusses are close to 30" high for the 40' span.

I'll post a few pics of the building tomorrow. My laptop crashed tonight. I'm on my iPad. But it's time for bed anyhow, past 11 pm!

[Simops]

Yea Andrew I was referring to the large sander......

BTW the spline is good way to join mitred edge....used that with box construction.....I can see your point being tapered legs......mmmm

You guys mention Naptha.....trying to work out what that is here?? Wikipedia says its a distillate of crude oil nearly but not quite kerosene....a hydrocarbon......and carcinogenic......nice! I think the closest equivalent here is called Shellite??? But I've never used it with any woodworking or painting here.....certainly not well known product to use......maybe because it's so nasty??

Cheers

BTW you have a bobcat.....what to shovel the snow away so you can get into your shop:p.

[Ajcoholic]

Naphtha here is very clear, viscous and fast evaporating. It's sold as a fuel for camping stoves and lanterns. Also used as a solvent. Kerosene is must heavier, oily and stinks. It is much slower evaporating.

I assume all the chemicals I buy for the finishing aspect of my job are nasty and use them accordingly.

[scottp55]

This link is good for the solvents we all use.
http://news.thefinishingstore.com/?p=357

[Ajcoholic]

I finished the legs this morning. After cutting the 45 angle on each side, I ran a groove on the table saw (using a plywood sled) and started gluing up the legs.

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[Simops]

So the spline worked out after all......good choice......certainly a neat way to make up solid looking legs with the Bot.....

Cheers

[curtiss]

Andrew does all that beautiful work and from his avatar he is just a stick person.

How do you plan your toolpaths to avoid chipouts which in that expensive material could be a disaster ???

[Ajcoholic]

Andrew does all that beautiful work and from his avatar he is just a stick person.

How do you plan your toolpaths to avoid chipouts which in that expensive material could be a disaster ???

In woodwork, few things are a disaster... Unlike other materials wood is so fixable! One reason I like I to much :D

For similar machining that I've done, I find roughing out cross grain, then doing the finishing pass along the grain works well. I've done a lot of maple, walnut, cherry and similar with no issue. Thus mahogany is somewhat harder and brittle due to the interlocking grain ( which hived it that ribbon like appearance) but machined just wonderfully.

If I did not say previously, I ran the 5/8" ball end spiral carbide bit at 10,000 rpm, feed at 480 imp and 120 I pm Z. With the current update software the bot is running very smoothly. I've been keeping up with the updates since last summer without issue at all.

[Ajcoholic]

Glued the other two legs, and just broke one corners on one to see what things will look like. Need to get some other work done next week, but I will spend a better part of a day sanding these and then I can start working on the skirt.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1819_zps2b386113.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1819_zps2b386113.jpg.html)

[dlcw]

Sweet!

That looks beautiful.

[rej]

your work in one word - class.
I love to see your work.

[Simops]

Andrew those legs came up really nice.....looks like one solid leg......perfect mitres!!

BTW what make is that RAS...? I still have my DeWalt 1251 that I bought new back in 1986.....still going well and recently put new table and adjusted it perfectly again.....will never get rid of it.....nostalgia I guess!!

Cheers

[Ajcoholic]

Andrew those legs came up really nice.....looks like one solid leg......perfect mitres!!

BTW what make is that RAS...? I still have my DeWalt 1251 that I bought new back in 1986.....still going well and recently put new table and adjusted it perfectly again.....will never get rid of it.....nostalgia I guess!!

Cheers

Yes they turned out pretty well. The miters closed up nicely and when the corners are rounded off and the leg sanded it should look nice :)

I sent a photo to the customer. She is quite excited!

The radial arm saw is an Omga, which is Italian. It's 4 hp I think, 14" blade. Nice saw. My last one was a Maggi (Also Italian) also 4 hp and we bought it in 1989. Still going strong in the old shop I sold in 2010. I hope the Omga lasts as long. I clean the rollers and guide rails every few weeks. If it's not silky smooth it bugs me.

I know bigger ras's aren't as common these days. But mine gets used a lot each day at work. Wouldn't be without one!

[scottp55]

Andrew, If those aren't "perfect" mitre's they're within a gnats a--. Mitre gauge, metal or one of those new fangled digitals I've put off buying because of my mobile base(I have to angle for boards longer than 10' and open garage doors for 14':))? Your son is going to love your mahogany "aircraft carrier":)

[Ajcoholic]

Did some work the past few days on the table... hope to start on the chairs next week.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1881_zps5dc9c10f.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1881_zps5dc9c10f.jpg.html)

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[Ajcoholic]

I used the shopbot to cut the slots and pockets for the table top mounting plates.. the screws go through the plates and allow the top to expand and contract seasonally.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1882_zpsc0f59be0.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1882_zpsc0f59be0.jpg.html)

[Bob Eustace]

Nice one Andrew!

[scottp55]

Andrew, Usually against staining, but that slight reddish/brown you were talking about might look good on table top. Do you tint your Danish oil and wet sand to fill pores with the stained dust? or do a 2-3 step process to stain/fill? Be a shame to touch the legs. Looks like your vertical/horizontal lines will have a strong but subtle definition. The oil is really going to make the legs pop:) Going to use the Buddy more on the chairs?

[Ajcoholic]

SCott,
I will try and do as much as I can on the CNC. I am probbaly not going to sculpt the chairs and bench legs as much as the rocker - and try and tie them in with the table & table legs as much as I can.

The bench - which is again going to have an 8 foot long seat - I am working on doing a carve along the whole length. My buddy can do 48" at a time. So I am planning to do it in two goes - one side then the other. Shaped like a church pew (at least the church pews I know - which are usually coopered around here) so like an S curve front to back. Not individual seats carved out as I have done previously.

I will post the Aspire drawing when I get it done. I hope to get started possibly this week.

I have a bunch of railings to install tomorrow, and then later this week (just waiting for the tile installer to finish up) I have a kitchen to install that will take me a couple days. Also I have three fireplace mantles I am just waiting to get the go ahead from the contractor to go and install. Then I'm back in the shop for the next several weeks - and hope to get cracking daily on this set.

[Ajcoholic]

Today, after working out of the shop all morning, I got the top and skirt sanded, and a coat of fruitwood Deft Danish oil applied. I am pretty sure this will be the extent of the staining (the fruitwood oil doesnt add much colour, but highlights the grain a lot and just evens out the variances in the mahogany a bit). Just needs to be lacquered.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1891_zps2f497561.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1891_zps2f497561.jpg.html)

Tomorrow I will finish sanding the legs and oil them up. Then on to the bench and chairs!

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[scottp55]

Wow, really evened out the wood! JUST right! Beautiful.

[Ken Sully]

Andrew,
Great work. Not sure where you find all of the time. Will you top coat the oil?
How many chairs will you need to make?

[Ajcoholic]

Andrew,
Great work. Not sure where you find all of the time. Will you top coat the oil?
How many chairs will you need to make?

well, remember one of us works full time... one doesnt. :D

I am at work minimum of 9 hrs a day... so things get done - eventually!

Yes I will be spraying this with several coats of post catalyzed lacquer. I often use a Danish oil to bring out the grain. Once it's dry (usually a few days) it is no issue to spray over it.

Just two chairs. One for each end. And the 8' bench for one side. They are using some other chairs for the rest of the seating.

Hey, my computer crashed a few weeks ago (got a new one now) and I lost your email and telephone #. Can you resend when you get a chance? Just trying to get my contacts back... Thanks Ken!

[Ajcoholic]

Spent all day hand sanding the legs, and got them oiled up just before quitting time..

The customer was in today. Colour is good (no further staining) and the skirt will be left as is. Now I just need to leave it for a few days and it is ready for the finishing room.

The legs I have decided will be attached with 1/4x20 bolts, and threaded T nuts - probably 5 per leg. Sometimes I use lag bolts, sometimes screws. This table will be assembled and taken apart a few times before it gets delivered to the customer so I will use the bolts to avoid any chance of stripping out a wood thread fastener.

More photos... tomorrow I start on the seating!

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[scottp55]

Well you certainly didn't scrimp on the sanding and they liked the oil! Wonderful wood and workmanship!

[Ajcoholic]

Nope, my hands are still raw today from 6+ hours of hand sanding yesterday...

But you have to do it. The faces were easy, but there is no machine I have that would sand the contours really well. Even though the ball end bit machined them really finely, I wanted to remove all the "lines" visible from the machining. The final sanding isn't the place to get lazy and say "good enough"..

Today was a pretty good day.

I managed to do a few things on the seating. First, I cut a sample of the seat contour for the bench. It was a little too deep, so I adjusted it and then got the 8' by 18" slab of mahogany onto my 48" buddy... and cut half the seat contour. Tomorrow I will flip it end for end, and machine the other 4' of the bench seat.

It was pretty easy to manage on the 6' powerstick, even considering the weight of the slab - and I was machining at 420 inches per minute for the finish pass.

I also got the parts rough cut on the bandsaw for the 2 chairs. Tomorrow I am hoping to get the two seats cut out and profiled on the CNC as well.

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[scottp55]

Andrew, Love the bench(No complaints from people with wide fundaments:)) and will be great for "Skootching over" for an extra place setting or an elbows on the table over coffee conversations.
I've never sold a thing in my life(always give away or keep) so always have sanded and oiled till "It's Done" which takes a ridiculous amount of time. Now the Northern Desktop(Take a right at the light-and you're in Canada) is starting to make product for sale and my methods won't fly. Getting acceptable finish with 4 coats Watco but first customer is screaming at price and wants lacquer and I have zero experience before this with either(varnish/oil/wax guy). Andrew, looking at the legs almost burnished look that makes you want to touch them--how fine did you sand dry? Do you wet sand? Only 1 coat oil before you wait a week to lacquer over Danish oil? I know it probably varies with species and project, but really like the way the legs are looking and wondering where the line of diminishing returns is when you have to sell stuff and stay in business. I'd like to stay high end of the market, but no business experience with wood.
Love to watch a craftsman's project unfold. I always do the "We're going to need a bigger slab!" route so very interesting watching the choices you make for glue-ups. Thanks for all the pictures.

[Tom Bachman]

Nice job, and a beautiful table!

[khaos]

I knw its been said, but that wood is just drop dead sexy. What a beaut!!!

[Ajcoholic]

Andrew, Love the bench(No complaints from people with wide fundaments:)) and will be great for "Skootching over" for an extra place setting or an elbows on the table over coffee conversations.
I've never sold a thing in my life(always give away or keep) so always have sanded and oiled till "It's Done" which takes a ridiculous amount of time. Now the Northern Desktop(Take a right at the light-and you're in Canada) is starting to make product for sale and my methods won't fly. Getting acceptable finish with 4 coats Watco but first customer is screaming at price and wants lacquer and I have zero experience before this with either(varnish/oil/wax guy). Andrew, looking at the legs almost burnished look that makes you want to touch them--how fine did you sand dry? Do you wet sand? Only 1 coat oil before you wait a week to lacquer over Danish oil? I know it probably varies with species and project, but really like the way the legs are looking and wondering where the line of diminishing returns is when you have to sell stuff and stay in business. I'd like to stay high end of the market, but no business experience with wood.
Love to watch a craftsman's project unfold. I always do the "We're going to need a bigger slab!" route so very interesting watching the choices you make for glue-ups. Thanks for all the pictures.

Typically, my sanding consists of rough machine sanding (random orbitals in various diameters and orbits - some quite coarse and aggressive and some very fine). I usually start off whatever I cannot put through the widebelt sander (like these legs) with 80 grit. Then 100. Then 120. I habd sand with 120, and then a maximum of up to 180 grit paper. On contours I usually go with an abrasive sponge which tends not to leave scratches on contours like paper does.

I never, ever ever go past that - some guys sand with 400/600/1200 etc and that is fine for a really good OIL finish. But, if you are spraying a finsih like the catalyzed lacquer I use, there is such as thing as "too smooth" - where the finish can possibly just peel right off the surface as there is no mechanical bond.

The thing you have to remember is, even though an oil finish might show the scratch pattern of sanding to 150 - a well done top coat finish (anything like lacquer, urethane, varnishes, etc) will not. They are heavy enough to actually fill and make not visible, these small scratches. Much like how a scratched plastic will look transparent when a light film of water is applied.

On most woods like maple, oak, etc sanding to 120 is industry standard. Fine sanding only takes place during the finishing process, not before. And, on darker woods like walnut, mahogany, cherry, etc that show scratches more - sanding to 150 or 180 is standard practice.

The practice of wet sanding, with the oil as a lube - is completely fine, if you are doing an oil and wax finish, but not if you are putting a top coat finish on a piece of furniture.

Make sense?

As far as finsihing in general goes - I do what I feel necessary to make the end result acceptable. For instance, making a table like this would be a complete waste of time IMO if you left the top or legs rough and they looked like hell.

This table is selling for close to $4000 - ($3750 if I remember my quote correctly). It better look like a $4K table... and as long as both I, and the customer(s) are happy, that is what matters to me.

[Ajcoholic]

Today I spent most of the day working on the bench. I thought I might get cracking on the chairs but that didnt materialize.

That being said, I ran the other half of the bench seat on my Buddy. Then, after some light carving to shape the ends, and some (well, quite a bit) of sanding... it was oiled up and I got started on the legs.

I decided the bench would look best with a skirt, and 6 tapered legs to go with the overall theme of the table. I've done others in the past similarly and they look good.

Here are some pics.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1919_zpsa470ef7e.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1919_zpsa470ef7e.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1922_zpsfee66394.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1922_zpsfee66394.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1925_zps4ef34712.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1925_zps4ef34712.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1927_zps17d1ff1f.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1927_zps17d1ff1f.jpg.html)

[scottp55]

I like it! Oh, and thanks Andrew, it made perfect sense and will save us a lot of time.

[Ajcoholic]

Got the bench done today... that's one more thing off the list.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1939_zps4395f6f2.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1939_zps4395f6f2.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1934_zpsb290affe.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1934_zpsb290affe.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1936_zps30427d36.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1936_zps30427d36.jpg.html)

Its quite comfortable!

[scottp55]

That looks suspiciously like more hand sanding:)

[Simops]

Andrew....nice work.....amazes me how quick you work......remember you must take breaks and don't deydrate:D

Anyhow a query.....did you experience any flex with that long 8 footer on the 4x4 Buddy table......it seems to me that all that overhang unsupported would surely cause some downward flex affecting the Z cut??

Cheers

[Ajcoholic]

Andrew....nice work.....amazes me how quick you work......remember you must take breaks and don't deydrate:D

Anyhow a query.....did you experience any flex with that long 8 footer on the 4x4 Buddy table......it seems to me that all that overhang unsupported would surely cause some downward flex affecting the Z cut??

Cheers

Well, the MDF table I have on the powerstick is 6'. So, with the 48" on the cutting portion, there was only 3 feet hanging off the MDF at a time. The photos make it look like more.

When the mahogany was clamped down, I tried to push down on the end of the slab and didnt notice too much if any flex.

I imagine it must move a little. However in a case like this, it wont really matter now would it? Not to me! :)

I have done some pretty large & heavy pcs on this Buddy. Last year I did two other bench seats that were nearly as long and as heavy.

I know some guys say "full size is king"... but I say the Buddy, with the 6' power stick is still pretty darn functional for a small furniture shop like mine.

As for working quickly - its a necessity. I need to bring in approximately $10,000 worth of work per month just to make my business profitable. I cannot take it easy - I have bills to pay, and luckily enough work to have a waiting list of months, year round :D

I just need another "me", in order to double my output. The one fellow I have working for the past year and a half is working out well. He does good work, but his output is quite a bit less/slower than I am.

[myxpykalix]

I can think of only one qualified assistant you could use, (which is another "me") but i'm not sure what the child labor laws are there where you live:rolleyes:

[Ajcoholic]

Well, here is a little update.

I started working on the chairs Wednesday. Here is where I am at..

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1954_zps2f9a6b65.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1954_zps2f9a6b65.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1953_zps99ac3852.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1953_zps99ac3852.jpg.html)

Its been a heck of a week. Busy at work - but finally got two other jobs out of the way. Were in the midst of another snowstorm.. Our water at the house has been frozen up since last weekend (a main on out street froze and burst last Saturday - by the time the city fixed it Monday - our home and several more on the street were frozen up... they aren't expected to thaw us out until early next week!) and Ive been hauling well water home from work all week. And my wife was out of town all week so I was looking after Joe full time.

I am hoping to spray the finish on the table & bench next week. And, with any luck get the two chairs done also.

AJC

[myxpykalix]

I just need another "me", in order to double my output
my wife was out of town all week so I was looking after Joe full time

I hope you had him with you in the shop with a piece of sandpaper in his hand?:D
It's never too early to get him started...:eek:

[Ajcoholic]

I just need another "me", in order to double my output
my wife was out of town all week so I was looking after Joe full time

I hope you had him with you in the shop with a piece of sandpaper in his hand?:D
It's never too early to get him started...:eek:

Not yet Jack but soon! He's turning three on Sunday... wild. Hard to believe it is three years that he's been around :)

I think I started hanging with my father around 5 or 6 in the shop. Joseph's attention span is still a little short for me to take him to work. But he likes to try and fix things at home - I gave him several screwdrivers, a pair of real pliers, etc to "play" with... ;)

[scottp55]

You just don't want him to see the big mahogany racetrack and six legged aircraft carrier you built him for his birthday:)

[Ajcoholic]

Some progress in the finishing room...

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1959_zps9c694208.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1959_zps9c694208.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1961_zps356f7f03.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1961_zps356f7f03.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1960_zps55102590.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1960_zps55102590.jpg.html)

Table top just sealed... needs to be sanded and several more coats applied.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1964_zps68c713a5.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1964_zps68c713a5.jpg.html)

[Ajcoholic]

chairs were glued up today. Just need to clean up the joints, final sand then oil and spray next week.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1963_zps10d40fd4.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1963_zps10d40fd4.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1962_zps39c6d786.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1962_zps39c6d786.jpg.html)

[scottp55]

Andrew, you've got me sounding like a broken record "Beautiful" "Gorgeous":)

[Ajcoholic]

finish sanded the chairs today, and applied the oil... next week will spray the lacquer and that will be the completion of this job.

Ill set up the table, bench and chairs at that point to show the customer. Will post a final photo(s).

AJC

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1966_zps018f22b4.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1966_zps018f22b4.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1968_zpsbed009e6.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1968_zpsbed009e6.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1969_zpsee2aea18.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1969_zpsee2aea18.jpg.html)

[scottp55]

Andrew, Until you threw the oil to them, It was hard to see how much attention you had paid to the grain layout(I should have known better and looked harder). They almost beg to be sat on. Especially like top boards,arm rests and seat grains. Like the asymmetrical backrest detail. Customer should be thrilled:D

[Tom Bachman]

Nice! Very Sam Maloof'ish inspired.

[Ajcoholic]

Well, I went in to work this morning, to have a look at the table top... wow its awesome! I was very careful in keeping everything clean, but it still took a little luck to get a top this large free of any dust & debris that can potentially fall on the fresh lacquer' surface and cause me grief.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1976_zps6e045c5a.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1976_zps6e045c5a.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1978_zps3dac9488.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1978_zps3dac9488.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1979_zps187cc5d5.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1979_zps187cc5d5.jpg.html)

Also sealed the chairs with two coats of lacquer.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1980_zpsbe941d8b.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1980_zpsbe941d8b.jpg.html)

I hope Monday to assemble the table and get a final shot of it all together, with the bench. And, hopefully finish spraying the chairs.

[scottp55]

Andrew, One heck of a lot better looking than my tax forms :) How many coats?

[Ajcoholic]

Andrew, One heck of a lot better looking than my tax forms :) How many coats?

Well, for the table this is what was done..

1-bottom side was sealed with 4 coats of lacquer

2-top side sealer coats - two passes (first cross grain, then with the grain) x2
then I drop filled any small checks, cracks, etc with thin CA adhesive (no kicker, just drop a little CA into the crevice and let it harden on its own.. makes a great filler that is transparent when overcoated.

3-then the whole top was sanded with a random orbital, with 220 to level off the finish and remove bubbles (mahogany is very porous)

4-repeat #2 & 3

at this point, even though I have technically sprayed the equivalent of 8 coats of finish, at least 1/2 of that was sanded off to level off the finish.

5-spot sand any dust/hair/bubble marks with 240 stearated paper by hand, then scuff the top with a medium (maroon) Scotchbrite, and go over the edges of the top as well.

6- two more coats of finish with the retarder added to slow down the cure time and let the finsih flow out really well.

At that point, cross my fingers, close the spray room lights and wait to see what it looks like the day after (which was today).

The grain is almost completely filled at this point with finish even though the total thickness isnt excessive. Some grain (texture that is) is still visible and when the finish fully cures in a few weeks and shrinks, a little more will be apparent. This to me gives the look of an older, hand rubbed finish VS a modern thick, polished out plastic looking finish.

I love the durability the catalyzed lacquer gives, but still retains the old school look of a wood finish that is relatively thin and not super glossy. Most of the gloss actually comes from the finsih being leveled out well by sanding, VS using a glossy finish. I am using a 35 degree sheen lacquer which is actually considered a satin.

If that makes sense... I compare it to looking at an old musical instrument. The new guitars have a thick, plastic like poly finish that doesn't show any "wood" character as the pores and grain texture are completely filled in and then the top coats built up to an excessiveness. Older guitars finished in a nitrocellulose lacquer show the subtle nature of the grains, etc through the finish and just look "better" to me.

[scottp55]

Andrew, Thanks for the point by point. Made perfect sense, but your clean room is bigger than either of our shops :) We could use a lacquer finish in our repertoire for the protection factor. Still using hand rubbed oils, and oil varnish blend as it's the easiest to teach beginners up North and a "close your eyes and pick" among 5 differently finished sections of a board, 90% pick oil. Dad went to a NE college Trade show in Vermont last week with a bag of samples and a guy that reps 15 colleges skimmed over them until he got to the oiled cherry crib board. He called the University of Vermont buyers over(They sponsored the show) and they forgot Dad was there as they started talking where to place it in the shop and alumni catalog and how much they could get for it:) Rambling. Thank you Again Andrew.

[JimDav]

Can't believe I am passing on a possible suggestion to MR Coholic but my piano tuners' son does high end restorations including pianos. To finish a piano top he hangs it upside down so nothing can fall on it as it dries.

[Ajcoholic]

Can't believe I am passing on a possible suggestion to MR Coholic but my piano tuners' son does high end restorations including pianos. To finish a piano top he hangs it upside down so nothing can fall on it as it dries.

Id not have the nerve to get under this top, if it were hanging in the booth upside down to spray... :) it would kill me if it came loose! :D

Interesting method though - makes sense for smaller or more manageable things.

Here is the table done, and the chairs. Another job just needing to be delivered. On to the next! :)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1985_zpscd926522.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1985_zpscd926522.jpg.html)

[Ajcoholic]

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1986_zps2c785bfd.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1986_zps2c785bfd.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1987_zps029c8886.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1987_zps029c8886.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1988_zps3b21821f.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1988_zps3b21821f.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1989_zps1f31d6a2.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1989_zps1f31d6a2.jpg.html)