We were commissioned to create a custom piece of furniture, for our lovely client who is opening a local interior design studio space. The design comprised of a 5m piece of 65mm thick elm.
The first step in the custom process was to cut one edge clean so it would butt nicely up-too the showroom window wall. The 3m festool track definitely comes in handy for this kind of work. Now this is no ordinary window shelf, its custom design has a ‘waterfall’ edge, which is an edge 90 degrees to the face that drops down the side. As you can imagine with a piece of timber this rare and expensive this became quite a pressured mitre cut… But what can I say we have balls of steel, oh and a little bit of skill !
Mitre cut complete, grain still flows, some sweating from the furniture maker but all in all extremely happy with the result. Its now time to ‘domino’ the joint. For those of you in the know ignore this next bit, maybe head of to the loo or make a brew… Domino’s are the miraculous invention by German tool manufacturer Festool, they are basically a jointing system that is quick and easy and extremely strong. The domino replaces the traditional mortice and tenon joint, which is not only time consuming but also needs to be done extremely accurately to give comparable strength.
Once the slots for the domino’s had been cut we now need to consider the clamping process for the waterfall edge. We need to ensure suitable pressure was applied to the mitre joint in order to form a strong bond. I decided to glue some angled blocks to the faces of the custom built vanity shelf. Although this would mean an extra process in removing them carefully with a chisel we felt it would be worth it to achieve the quality of joint
I should mention at this stage that although we cut the mitre joint with the track saw, in order to finesse the joint with the hand plane a full day was required to get the joint absolutely perfect so that the faces met perfectly all the way along the joint.
Anyway… this hand crafted, custom built piece of furniture was now really taking shape, a few deep breaths and we applied the glue and bonded the waterfall edge to the main shelf. Four Bessy clamps were added to the blocks to apply the necessary pressure to the joint, then we went for a cup of tea and a lie down!
The day after… hey presto the waterfall edge lives! I was extremely happy with the results, the grain flowed beautifully around the joint, and the joining of the custom built furniture had gone really well, but then…..
Our client requested a radius edge to be planed into the edge. We had foreseen this could be a possible situation so I had set the internal domino’s back, just in case. The only slight draw back to this is that we would loose some of the grain consistency around the edge of the shelf. But a 65mm radius was selected and we set to work with the hand plane.
I’m not sure… what do you think? I did like the really crisp edge, but the custom built shelf does now flow really nicely down its waterfall edge with the radius applied. Anyway its almost time to select the surface finish, just a little bit of chisel work required on the edge then it would be out with the matt Osmo.
WOW!!! Look at that grain, its magic really, look what happens when solid timber is sanded and finished with Osmo. We love Osmo for our custom built hand crafted furniture, as it looks great, it brings out the natural beauty of the timber, if cared for it is extremely durable and the best of all there are no ‘nastie’s’ like you get in sprayed finishes.
And that my friends is that, a beautiful solid elm custom built piece of furniture. We will keep you posted when we actually deliver the piece to the new showroom and post some pictures of this beautiful piece in-situ.