Tuesday 31 December 2019

A tall corner cupboard from rough reclaimed wood

Here's a tall cupboard I made for the corner of the sitting room.


Its quite discrete. It's mainly just a plinth for popping vases or flowers on. It does open and has two shelves for storage if needed.


Build

This one is definitely NOT a cabinet making showpiece. In fact there's not a single proper woodworking joint in it. I knocked it up in two days to fill a space in the living room. It is a companion piece to a trunk I made recently.

(see https://makingweirdstuff.blogspot.com/2019/12/making-table-into-trunk.html)

This one was made from some old reclaimed hardwood baulks and some cheap packaging-crate ply. The main effort was in antiquing the finished piece with a bit of blowtorching and a lot of shoe polish.

Here are the "designs" for the main elements of the basic carcass. It's two rectangular mitred frames with ply panels for walls.


The design shows corner bracing (in the plan view). In the end, I didn't bother with this.


Translated into wood, it ended up like this...


Here are the frames. Mitering the corners is as close to proper joinery as I got here. I guess these could be called pinned mitred butt joints, but that's a bit flowery. To be fair though, they are stronger than one might imagine. They are glued, but it's the screws that hold them rigid. You can do this with a good hardwood like this. It is less effective with basic softwoods as they spilt too easily.


The "joinery" is simply two screws on each joint to pull the mitres together. This works pretty well with this old mahogany type wood (it might even actually be a mahogany, as it was reclaimed from discarded casements from a library at the Natural History Museum).


The joints just needed pilot holes and a countersinking. With a hard timber like this, the wood will split every time if you try driving a screw into it without doing either of these two things.


But as long as the prep is done, the screws tap in beautifully and the joints are really strong.


The basic cabinet is very basic. Just three pieces of cheap plywood scavenged from old packing crates. This is strong, but the finish is generally pretty poor. You can see how rough the finish is on one side in this shot of the panels.


The panels were fixed into the frames with screws. PVA wood glue was used so these joints are really strong.
The roughness of the plywood is actually a good thing when gluing as the fibres are exposed and the glue can get a good purchase round them.


Prior to screwing, the panels were held in place with cramps...


Some classy joinery there. Gaps like this were filled with PVA and sawdust and once dry, sanded down.


A close up of the fine craftmanship on the vertical panel joints...


The vertical joints have no jointing apart from butting up of the perpendicular panels. To stabilise them, they were glued with PVA and pinned.


The panel pins were driven halfway in then had their heads nipped off...


Thus...


The fairly tiny pins could then be punched discretely into the panels...


The top panel and the door front were from a very nice piece of an old tropical mahogany-type hardwood. This came from from an old wardrobe. I don't know exactly how old the wardrobe was, but no later than early 20th century, possibly late 19th century.


The panel was cut very slightly oversized. It was then trimmed with this nice old plane...


Until it could be squeezed into its slot nice and tight...


To get the panel to drop down to the right depth needed a bit of a plane with the edging block plane.
Any excuse to use lovely hand tools...


Once it was tight, it was glued in with PVA.


I used PVA and sawdust to fill in any gaps...


Later on after the glue was set, any slightly raised edges were planed down smooth to level them with the edging frames


And all were sanded smooth...


On the mitred corners, where there was any slight overlap, I used a rotary burr in the die grinder. This can file down end-grain without jarring it, like a plane sometimes does. This avoids splitting it.



The shelves were just sheets of ply. To make them slightly classier, I tacked and glued on some hardwood strips. Here, the pins are having their heads nipped off before being punch in.


The door was built with some cheap T-hinges and a piece of the rough ply.


Once the basic door was functioning the decorative front panel was screwed on.


The door panel once fitted...



Finishing

The raw wood was a light sandy-brown. The richer dark reddish-brown came from using ordinary shoe polish. This is dark tan.


Shoe polish is basically wax with dye in it. This is the colour after the first application.


Here is the front panel of the door with the polish just being applied. You can see the difference in richness and darkness of colour between the raw sanded wood and where the polish is applied.


Antiquing

Although the basic polishing gives a good colour, some additional richness was added using a blowtorch to scorch the wood.


So here is the side panel, which has been polished, but is a bit plain.


Out with the blowtorch...


The scorching gives darkness. This is more easily controlled on the solid hardwood pieces. On the plywood, more care is needed. It is quite easy to burn a hole in the top layer.


After some random darkening, some pseudo-grain was scratched into the surface using a coarse (60 grit) sandpaper. This looks a bit rough when you do it. The scratches made by the grit look light when first made.


Once re-polished they deepen into a darker brown to mimic grain.
And it all starts to get rich and old-looking...


Similarly, the door panel was scorched in diagonals and scoured back in the same way with the rough sandpaper. This sanding is best done with very light pressure or the scoring causes grooves.


The finished door panel, after re-polishing. The nice mottled grain is all faked. The original panel is almost completely uniform in grain and colour.




Sunday 29 December 2019

Christmas cracker mayhem 2019

It's that time of year again

Time to face just-about-tolerable levels of risk of physical danger from dodgy homemade christmas crackers.  This year's "crackers" were actually christmas sacks, but with firework heads. Normally I'd make boxes, but sacks are much quicker to make and can be sewn to any size easily.

Each wooden head is a piss-takey caricature of one of the dinner guests. Each one provides the crack by firing off a decent bang using gunpowder. They are essentially cannons. This required a lot of carving, given we had eight people at dinner and two honoury guests absent, but attending in spirit (one of whom is a dog). Four of the heads had been made for previous years. This still left six heads to carve.

Here are all ten. These were oak, birch and what I believe was pear, but can't be sure.



Action shots

These shots are from a smoke test I did to decide if they could be used indoors. 
Pretty conclusively the answer was NO.







Making

All these heads were carved from semi-green wood.
What better raw material than a LUMP OF TREE...

The process for creating a head from a piece of log is, (more or less):
  • Get log and cleave off piece of a suitable size for whatever you are carving. I used scavenged oak (hard and dense), birch (soft and light) and pear (somewhere in between).
  • Depending on how green/wet the wood is, leave inside a dry shed for a month or five ( if really green and wet)
  • Find a pic of the person you are basing it on
  • Make some drawings of the person to get a feel of the shapes of the head (this is important - in your mind, you need to be able to see something like the finished thing)
  • Work up a few final drawings to base the cutting on. These may need to include block-shape drawings that are not detailed
  • Get log piece and hack down a square base for holding it securely in the vice
  • Carve out block shapes of head. Typically using axes, rough saws, the Arbortech
  • Re-draw details on block shapes
  • Carve down to next level of detail, using die grinders with large burrs
  • Carve down to next level of detail using small rotary multi-tools (Dremel scale) and micro burrs
  • Sanding down increasingly fine grits and steel wool

The raw materials

Hey. Guess what. Wood is made from trees. Here are some logs from a felled birch tree. They were too big when found, so after getting them home, I sawed them to the right length and then split into blocks with an axe.


Prepping the wood for carving

Here's an axe-cut block. A freshly hewn block like this is always uneven because of the grain. This makes it hard to hold firmly enough in the vice. When carving, you need the wood to be secure.


The first thing to do was to make a square end for holding the block in the vice.

This was done with the Arbotech. I love my Arbotech. This is the wheel-shaped blade on this angle grinder. It cuts even oak like butter.


A simple squarish end like this is all that was needed to be able to hold the block in the vice whilst carving
it

Another method is to screw on some square blocks to the base of the log...

Drawing

Before starting carving, I like to fix the image of the finished carving in my mind by drawing the subject several times. I do this by copying photos. Once a few drawings have been done, the image is sufficiently fixed to be able to distort it into a caricature. Having a conceptual target model allows me to carve out the shapes without always having to check back. Essentially, if you know what the the final shape is in your mind, you can carve away towards it. 

Here's one.


They don't need to be perfect...




















Roughing

Once familar with the shapes, the approximate block-level shapes can be drawn onto the log as a guide. These do not need to be too detailed. In fact they should NOT be very detailed. When blocking out it is not good to focus at the detail level.



Sketching out for roughing can be pretty minimalistic. At this stage, the big blocks of space are being formed.. Marker pen is good for this. It is hard to draw detail with a marker pen.


One of the trickier things is drawing flat drawings onto a 3D block. This requires a repeating process of carving and redrawing. As the shape emerges on the wood, this gets easier.


This is the first pass at roughing out a shape. This is a dog.


From the side, you can see the angle of the end of the muzzle starting to emerge...


Some time later. Note the redrawn guide lines...


Some more time later...


The blobs start to become more detailed...


Here's another one...


Because carving out the shapes cuts off the wood, the lines need to be repeatedly redrawn...


From the side too...


And the back...


Halfway through roughing out. It is always good to keep a rough sketch to hand to check the shapes.

Note that there are different details of sketch needed. Rough sketches are blob-level shapes...


More detailed sketches should not be used at the start, but are useful once the basic shapes are hewn...



This head is starting to take shape...


Here is an early block. Note the massive nose...


This was needed to carve out the more subtle shape of the final nose...


Sometimes you need to check back to the source photo...


And just keep redrawing...


This is where having the final image in your mind helps to allow new guide lines to be drawn...








Another one...





Details

Eventually, the heads can be refined. This one is almost done for shaping out. It mainly now just need cleaning up and sanding etc....



These were all carved using an Arbortech, 6mm rotary burrs in a die grinder and 2-3mm burrs in a Dremel. This makes a lot of sawdust



Me and my son...


Each head was the bang. The innards of the "cracker" was a sack this year.


Smoke testing

I wasn't sure we could get away with lighting these indoors, so I did a dummy run top see how much smoke and flames they'd make.

I fitted fuses to each and joined these to a central control fuse...


Charged each head cannon with gunpowder pellets...


And set them up outside. In the shed would have been madness with all the sawdust in there!