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Ajcoholic
10-14-2016, 07:24 PM
A few weeks ago I was contacted by a customer of mine, and asked to make a large (48" by 100") walnut table with a slab top, and very plain overall appearance.

Surprisingly, my normal wholesaler was able to quickly source me some 12/4 black walnut, in 10' lengths and pretty darn good stock at that.

I wanted to do something other than just have a "plain" base trestles (their initial idea) so I proposed using some walnut burl veneer from my private stash - and making some panels that would be set into the trestle faces.

Another easy job with the CNC router (and not so easy without).

I laminated the 32" wide by 27.5" panels (all 2 3/4" thick) and pocketed the two sides on the router. Yesterday I vacuum bagged the burl veneer onto a piece of 1/4", and today I cut the panels out on the CNC as well.

Took 4 minutes to pocket each face of the trestles, and about a minute per panel to cut out (all with a 3/8" spiral). I allowed 15 thousandths clearance, and they slip fit ever so nicely into the pockets.

Here are some pics.. I just finished sanding the top and trestles before the end of the day, and applied a coat of clear oil to bring out the grain. Will be finished next week with post catalyzed lacquer.

The burl panels after layup...
http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic044/image7_zpsspl7kg4m.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic044/image7_zpsspl7kg4m.jpg.html)

Cutting the panels. I do a pass climb cutting, almost all the way through, then a conventional pass cutting through. Everything held down on the universal vacuum table.
http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic044/image5_zpsbibsohdj.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic044/image5_zpsbibsohdj.jpg.html)

Pocketing the trestle panels..
http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic044/image4_zps60sfh45k.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic044/image4_zps60sfh45k.jpg.html)

And the panels set into the trestles (set down 1/4" from the face)..
http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic044/image3_zpsdc4wvyn0.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic044/image3_zpsdc4wvyn0.jpg.html)

Ajcoholic
10-14-2016, 07:25 PM
And the top. For lovers of walnut only! lol..

http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic044/image2_zpsollfxiwo.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic044/image2_zpsollfxiwo.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic044/image1_zpsvodosslk.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic044/image1_zpsvodosslk.jpg.html)

Tim Lucas
10-14-2016, 08:06 PM
Beautiful !!

cowboy1296
10-14-2016, 09:18 PM
I luv black walnut. Here is an update on my slab table made from bubinga. I stole an idea off of internet and had made a 4 inch industrial i-beam stand which weighs in at 250 by itself. Now when i got http://www.talkshopbot.com/forum/attachment.php?attachmentid=29106&stc=1http://www.talkshopbot.com/forum/attachment.php?attachmentid=29107&stc=1the board it was satin. I am interested in taking that to semi gloss to a gloss. Its to heavy to move so i need to do it in the house. So any ideas i am all ears

Ajcoholic
10-14-2016, 09:52 PM
Why did you need those metal straps on the underside?

Any finish can be polished up in sheen. To go to a high gloss, my general procedure is to went sand with 400/600/1200 grit wet and dry paper (using a bit of dish soap in warm water as a lube). Then I have 3 grades of polish I use on a foam or felt pad on a pneumatic rotary buffer, and finally a swirl remover for the final polish. That will get you to a mirror finish.

Requires you have enough material on there in the first place though, to work with.

Bubinga is another favourite of mine. I was thinking of a bubinga panel in the base of this table, but decided the burl walnut was less contrast and would suit the look better for this one.

cowboy1296
10-14-2016, 10:31 PM
Its not straps but angle iron. Since i bought the slab used i can only assume that the original builder was trying to prevent warpage or even splitting. The slab by itself weighs in about 300.

Once you have polished the table is it susceptible to scratching? What polish do you use or does it matter? What do you mean by material?

Thanks for the help.

Ajcoholic
10-14-2016, 11:09 PM
Its not straps but angle iron. Since i bought the slab used i can only assume that the original builder was trying to prevent warpage or even splitting. The slab by itself weighs in about 300.

Once you have polished the table is it susceptible to scratching? What polish do you use or does it matter? What do you mean by material?

Thanks for the help.

By material I mean you need a minimum film thickness (of whatever is on there) in order to wet sand and polish up.

The wet sanding is to flatten the surface. If you try and polish a finish without first leveling it off, you will make it shiny but you will also see every imperfection/bump/etc.

If I am starting with a good finish on a flat surface I will start at 600. Dont sand too long without drying the surface and looking at the progress... it is easier than you might think to burn through the finish and while wet, you wont notice until it is too late.

For an easy want to add some shine (if you arent trying to get a piano finish) just lightly sand with some 400 grit, then go to 0000 steel wool and some vaseline for a lubricant.

I thought you made up the top, hence my question. So the angle is routed into the top then... prob to try and keep to flat Id guess.

I am going to fabricate some steel plate/angle to attach these trestles to the top. The customer doesnt want any stretchers between the base pieces.. so I will have to make sure they are very securely fastened to the top to prevent racking.

Ajcoholic
10-14-2016, 11:13 PM
Once you have polished the table is it susceptible to scratching? What polish do you use or does it matter?

Any glossy finish will show wear and tear more than a duller one. How easily it scratches is dependent upon the finish and hardness of the finish.

You can use any compound for rubbing out and polishing paints/lacquers/plastics etc. Automotive products are easier to get - just a series of pastes that are of varying grit. Usually come in a can or tub mixed with either water or some sort of solvent to form a paste. Car buffing supplies (not wax, but the stuff used to go from a wet sanded finish to a gloss, same as you want to do with your table), musical instrument buffing and polishing supplies, etc.

steve_g
10-15-2016, 12:19 AM
Wow! Very nice! You’ve really got me excited about some Walnut we just put in the kiln… I image there will be some tables in that batch!
SG



http://www.talkshopbot.com/forum/attachment.php?attachmentid=29111&stc=1http://www.talkshopbot.com/forum/attachment.php?attachmentid=29112&stc=1

cowboy1296
10-15-2016, 07:01 AM
Looking at all of that black walnut is like being in a man's candy store. Thanks for the advise and help. As much as i like the top, its not perfectly smooth so i think that i will listen to your warning.

dmidkiff
10-15-2016, 07:34 AM
Beautiful table Andrew. I really like the walnut burl. It's going to look amazing when together. Bet the owner doesn't cover it up for a least the first year so it can be admired when passing by.

scottp55
10-15-2016, 08:19 AM
Took me second to realize the burl was on both sides of the base:) (Nice!)
Not that I'll be veneering, but what was the .25" substrate Andrew?
I Like your choice of the center board, Kinda hard to be a "plain" table with all that figure:)
(nobody warned me I'd need a drool bib if I opened this thread :) )
Make sure to post a pic of support angle because of lack of stretcher please.(have a 10' Hop Hornbeam dovetailed slab bench that has to straddle an 18" tall subwoofer and have been dithering for for 15 yrs about a support angle....AND can't move the sucker by myself anyways(10/4) )
LIKE how it "popped" in places:)
scott
OH, Steve...how long had logs been on the ground? Just wondering as my uncle still hasn't slabbed the Black Walnut my aunt cut down in August, and want to give him a kick if they winter as logs and will get pithy in sapwood.

steve_g
10-15-2016, 09:07 AM
Scott…
A friend of a friend offered us the log, it had been on the ground for 3 years! It won’t be good “live edge” material as much of the sapwood is not sound. The heart looks really good but perhaps not as dark as might be expected. I’m really anxious to put a finish on some of it to see what it looks like because he has another “much larger” log… he just can’t remember for sure where on his acreage it is!
SG

scottp55
10-15-2016, 09:39 AM
Thanks Steve.
His 3 12' lengths should be good then, as they're resting on landscape timbers and the tops are covered:)
BTW, On the shorts he cut, those little "twigs" stopped the cracks in their tracks, but probably because it dimensioned out as only 1.2" and I did the .27" twigs on both sides within a few inches of each other. Wood is still shrinking though(the butterflies WERE flush, and now very slightly proud).
Sorry off topic Andrew:(
scott

Ajcoholic
10-15-2016, 05:45 PM
Dont worry, ill post how I attach the base when its is done. Also, no worries on the thread - I wish I had some walnut logs here. We are in the middle of black spruce and jack pine country. Some paper birch (small trees) and poplars here but predominantly softwood that is cut for construction grade lumber and pulpwood.

I know a chair maker in Southern Ontario (about 8 hours drive south from me) that has a small sawmill and cuts/dries a lot of walnut and cherry that he gets from his area, and some maple too. Ive seen piles of his wood... it makes me envious! If you remember that curly maple rocker I built about 3 years ago, I got that wood from him.

scottp55
10-15-2016, 07:05 PM
Whew:)
I certainly do remember that rocker:)
Drooled all the way through the thread, and also showed my ignorance of Sam Maloof(fully rectified now).
I just mentioned that chair to Robert R. on Friday, when we were talking about his visit to my shop next week and he said he met you.
Things that pretty stick in your brain.
I'm jealous of Steve's stash every time I see pics of his loft.
Hoping to cherrypick some of of that Walnut from my uncle once he cuts it to replenish my stash(got some NICE double crotch in 3 pieces I think, and mentioned to cut some 8,10,and 12/4 out of it).
Hard to have too much special wood.
Thanks Andrew!
scott

Ajcoholic
10-16-2016, 01:00 PM
Whew:)
I certainly do remember that rocker:)
Drooled all the way through the thread, and also showed my ignorance of Sam Maloof(fully rectified now).
I just mentioned that chair to Robert R. on Friday, when we were talking about his visit to my shop next week and he said he met you.
Things that pretty stick in your brain.
I'm jealous of Steve's stash every time I see pics of his loft.
Hoping to cherrypick some of of that Walnut from my uncle once he cuts it to replenish my stash(got some NICE double crotch in 3 pieces I think, and mentioned to cut some 8,10,and 12/4 out of it).
Hard to have too much special wood.
Thanks Andrew!
scott


Say hello to Robert for me please? We hung out together twice when we attended the McGrew's Aspire event in 2014/2015. He does some amazing metal work on his Shopbot.

I have a little stash here and there in my shop of solids and veneers. Some rosewoods (blackwood, cocobolo, Indonesian RW) pau ferro, some figured stuff, etc. A plank of ebony or two.. and veneers.

They come in handy like for this table, or for the dining room set we delivered last week that I made up cocobolo knobs for. A little extra special something.. :)

I buy the odd piece of wood "just because" every once and a while. Even if it is dearly priced. For me, I'd rather spend some money of a nice plank, and sit on it for years, instead of buying something for myself. I really do love wood!

scottp55
10-16-2016, 01:35 PM
Certainly will Andrew(he's probably reading this:)
My Dad is in town that day and he's a metal CNC guy, and will drop by for half hour for a cup of tea:)
Wasn't Pau Ferro one of your Dad's favorite woods and used somewhere in that rocker?
"Plank of Ebony" I'm jealous...only have 3 small billets left from the 90's(excellent in wet area like baths as accents to Teak with a Tung finish)
IF I can cherrypick some of uncles Black Walnut it will come out of my food budget:) (and well worth it)
I'm having fun with just the branches I salvaged.
Still interested in a non stretcher solution that meets your standards of heirloom stuff.
Did you sell that chair for two arms and a leg...or did you keep it?
Looking forward to next week!
scott

guitarwes
10-17-2016, 09:31 AM
Super nice work, LOVE the burl inlay. Walnut is beautiful but it's a shame that a lot of it around here is cut down and burned for firewood. Most people don't like dealing with the mess of the falling nuts.

Ajcoholic
10-18-2016, 06:40 PM
Yesterday I fabricated the metal brackets to hold the base panels on. Today I routed them into the top and used the shaper to machine the panels to accept the brackets. Bolted the works together.. success!

Pics later tonight. I'm at scouts with my son right now.

Ajcoholic
10-18-2016, 08:20 PM
OK, here we go. Please dont critique my stick welding, it is functional but not pretty! I know! lol

Firstly, I cut some 1 1/2" steel angle to length and welded a 1 1/2" wide steel plate in between. I made a wooden jig, tack welded the pieces then removed the wood and welded along the lengths. Then I welded two pieces of 1" steel angle to the top, and drilled some holes for the lag screws. Three 4" by 3/8" lags into the base panel and 4pcs 2" lags into the top - with two brackets per panel.

The panel shouldnt move enough where the 3 lags are screwed into it to cause me grief. And overall, the panel and top will move together so everything should remain stress free with seasonal movement.

With the panel, I machined two 1/8" slots deep enough to accept the steel angle, and then undercut it so the steel plate in between the angle sits tight on the wood after the lags are screwed home. The underside of the top was routered to accept the brackets, so the bottom of the base panel sits flat on it and the bracket is completely hidden from view.

It worked great. Extremely secure. You cannot feel any movement in the table when standing at one end and pushing on the top.

SOme pics...
The base panel machined to accept the brackets
http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic045/IMG_2097_zpsqwbdsk1w.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic045/IMG_2097_zpsqwbdsk1w.jpg.html)

Brackets
http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic045/IMG_2098_zpsw5kuuy7v.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic045/IMG_2098_zpsw5kuuy7v.jpg.html)

Bracket fit into the base
http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic045/IMG_2099_zpsh6g5lm8p.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic045/IMG_2099_zpsh6g5lm8p.jpg.html)

Fitted to the top (no lag bolts in yet)
http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic045/IMG_2101_zpszywaq9tb.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic045/IMG_2101_zpszywaq9tb.jpg.html)

Ajcoholic
10-18-2016, 08:22 PM
http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic045/FullSizeRender_zpsheiksixg.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic045/FullSizeRender_zpsheiksixg.jpg.html)

On to the finishing room..

Ajcoholic
10-18-2016, 09:03 PM
Wasn't Pau Ferro one of your Dad's favorite woods and used somewhere in that rocker?

"Plank of Ebony" I'm jealous...

Did you sell that chair for two arms and a leg...or did you keep it?
Looking forward to next week!
scott

Scott, you have a great memory... Pau Ferro was used as an accent strip in the rockers. And yes it is one of my father's favourites.

I have one board of macassar ebony about 5' long, 5 or 6" wide. Its a nice one, Ill hate to cut it but will once the right job comes along.

I still have the chair.. in storage as no room in our house for it. I use it for the annual home and trade show here, it always attracts attention. But I would sell it if someone wants to plunk down the cash.. :)

Tom Bachman
10-18-2016, 10:56 PM
Gorgeous table! Very ingenious way to mount the pedestals.

scottp55
10-19-2016, 03:37 AM
I think that table is getting into the Ali Baba Bench category Andrew!! :)
When an older Roycrofter (groundskeeper/gardener?) built a bench so he could sit in his favorite spot...he went overkill considering his age.
When asked why he went so massive he said(paraphrased..memory isn't That good:)

"I built it so that it would outlast me...so that other generations will enjoy it besides me"

Always stuck in my brain like Pau Ferro(I look up new woods in Wood Database immediately so it sticks to my few brain cells:) ), and it was easy to remember because of an Ali Baba style Indian Rosewood wall table I made, and linked the wood in my head to Rosewood workability.
I didn't realize the Roycrofters made more of them until today...LIKE the "99 year warranty" as much as the original $10 price!
Thanks for the pics and steps Andrew!
Robert in 6 hours...wish you hadn't left the teaser when you were at scouts...got my brain going to much to sleep.
One Rugged and Beautiful table!
scott

Shame about the rocker in storage...VERY nice Master's Piece!
Also a shame Elbert Hubbard went down with the Lusitania:(
https://books.google.com/books?id=oRPkOvty7u0C&pg=PA61&lpg=PA61&dq=roycroft+alibaba+bench+history&source=bl&ots=vnyLUe9gIK&sig=p_N9bD-BUrVCmIXohDsvepRFIp0&hl=en&sa=X&ved=0ahUKEwjD06zOqObPAhXD5CYKHWKlAggQ6AEILjAD#v=on epage&q=roycroft%20alibaba%20bench%20history&f=false

Ajcoholic
10-23-2016, 05:12 PM
Started sealing the table friday... post some pics over the next few days. But man, it never fails to impress me when you get some clear lacquer on Walnut, after its been oiled. Just brings out all the subtle highlights in the wood.

The burl also looks amazing. I was saving that stuff for a long time. I am sad to have used 1/2 of my stash, but happy it went to a good home/use.

Pics probably tomorrow night if I can manage to get the table buffed and a few more coats applied. I need help of course to handle the top, and we are doing some install work just outside of town (stairs and railings, and a large barn style door) so I might be out tomorrow with the guys.

Bob Eustace
10-23-2016, 06:12 PM
Looks fantastic Andrew - where to next?

Ajcoholic
10-23-2016, 08:48 PM
Looks fantastic Andrew - where to next?

Well hopefully to the customer's house in about a week. :)

If you meant work wise... I have a few smaller kitchens to do, a set of doors (for a kitchen), we are working on a fairly large stair and railing job right now, as well as some more stair components for another contractor. I have a large desk and millwork coming up as well. Oh yes, a storage chest / cedar chest as well.

CNC wise, I have a large mahogany buffet to do that has been on the table for over a year. That will have a heavily carved front face. Finally going to get to that I hope early winter. Luckily I generally have many months of work booked in ahead.

I have another kitchen to cost out this week as well. Been fairly cabinet heavy the past year. I am hoping more furniture comes along, but it will.

scottp55
10-24-2016, 06:31 AM
Andrew,
I noticed in the oiling pic, the oil on underside barely went in past an excess wipe?
IF it stayed that way, can you post a pic of the transition area when you Lacquer, so I can see the difference the oil makes vs just the Lacquer?
Had a guy say there was no difference, and "Why waste a week?" I strongly disagreed with him, but had no pics to back it up as I don't lacquer anything.
Thanks.

Ajcoholic
10-24-2016, 07:39 AM
Andrew,
I noticed in the oiling pic, the oil on underside barely went in past an excess wipe?
IF it stayed that way, can you post a pic of the transition area when you Lacquer, so I can see the difference the oil makes vs just the Lacquer?
Had a guy say there was no difference, and "Why waste a week?" I strongly disagreed with him, but had no pics to back it up as I don't lacquer anything.
Thanks.

Makes a huge difference in enhancing the grain. Doesn't change the colour. But brings out the grain. Any top coat finish which doesn't penetrate into the wood doesn't really do this. The oil does. I'll show you an example.

Ajcoholic
10-25-2016, 09:37 PM
Finish is done... many coats with sanding in between. Super smooth and silky soft.. :)

http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic048/IMG_2136_zpshoa404si.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic048/IMG_2136_zpshoa404si.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic048/IMG_2137_zpsikpaafmz.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic048/IMG_2137_zpsikpaafmz.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic048/IMG_2134_zpsmf6tir8e.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic048/IMG_2134_zpsmf6tir8e.jpg.html)

cowboy1296
10-25-2016, 10:01 PM
now i am jealous, great job

scottp55
10-26-2016, 07:08 AM
I don't see why you're jealous Rick?
Andrew has obviously failed making a " very plain overall appearance" table. :) :)
Grain patterns on left side "Celebrates" the differences in the wood beautifully Andrew!!!
Congrats!
scott

guitarwes
10-26-2016, 08:53 AM
Beautiful. I love how you left the sapwood and the grain patterns are all varied. Real wood. Real stuff. :cool:

Simops
10-26-2016, 07:51 PM
Walnut.....love it but I can only get as 8 quarter as an import here because so expensive......you are lucky in North America to have that wood so readily available in those sizes. Nice to work with and machine.

Andrew nice job and I do like the way you attached the base to table......I will definitely keep that in mind....

BTW was in Toronto a few months back visiting relatives and a wedding.......visited the Lee Valkey store.......wow!! Nothing like that here.

Cheers

Ajcoholic
10-26-2016, 10:23 PM
Thanks guys, the customer wanted a "real wood look" - ie not uniform. I actually wish there was more sapwood. Plan to deliver it Monday, so will take a last photo of it assembled in the house.

I was surprised how easily my supplier got me this 12/4... but man was it pricey. I paid nearly $14/board foot for this stuff.

Brian Harnett
10-28-2016, 10:15 AM
Looks great, the customer will be happy for sure, always a good feeling.

Ajcoholic
10-31-2016, 09:55 PM
Delivered today.. took three of us and the customer`s help too..

They are super happy with the table. Now they need their new area rug and chairs they ordered to come in and I can get a finished photo.

But my work here is done... :)

http://i83.photobucket.com/albums/j307/ajcoholic/ajcoholic049/walnut%20table%20delivered_zpsigouomv9.jpg (http://s83.photobucket.com/user/ajcoholic/media/ajcoholic049/walnut%20table%20delivered_zpsigouomv9.jpg.html)

scottp55
11-01-2016, 09:06 AM
Elegant Andrew!!! :)