| Blog series by bfd | updated 480 days ago | 5 parts | 1559 reads | 51 comments total |
Part 1: The design
> > This is my latest project which I am about to undertake. It is a Tea Cart that was sketched by my client. She wanted an Alvar Aalto inspired tea cart and she designed this piece and asked me to build it. There will be a lot of challenges here for me. The biggest challenge will be the bent wood lamination. The client has selected quarter sawn white ash with a slight fiddleback figure to it. The top tray will be ash with white glass mosaic tiles while the bottom tray will be all a...
Part 2: The Wheels are in motion!
The first order of business was to start on something simple for this project…Cutting the wheels. Since the client wanted painted wheels I decided to do them out of MDF since it will be stable and paint out very well. Using my homemade circle jig I set the jig to cut a 14”DIA circle. Taking a light 1st pass I go down to about 1/4”. I then took my jig saw and followed just inside the outer edge of my router cut to remove the bulk of the material. I then followed up with m...
Part 3: Refining the laminations and underwater basket weaving
Did I mention how over my head I am with this project? Well after taking a week off from woodworking between a trip to Vegas and not being able to work in the shop due to the smokey air in the Sacramento area I am back to work. Now that I have the laminations glued up I needed to figure out a way to trim them down to finished width. I intentionally glued the laminations up at 3 1/2” knowing that I needed to yield a 2 1/2” wide leg. This was a challenge since I couldn’t u...
Part 4: Fixing a routing mess up.
So seeing how woodworking is largely based on problem solving I tought I would post this to show you a recent problem that I had to solve. When I was routing the edge of one of my bent laminations I accidently nicked the sides leaving a nasty gouge. My heart sank thinking how much time and money I have invested in these laminations so far. Knowing that if I replace one lamination I would have to replace both since that they are matched from the same flitch of veneer and I would seriously ea...
Part 5: Making progress ... I think
> So here is a quick update of where I am at. I have been busy building the upper and lower tray as well as figuring out the wheel connection. here are the two tray bottoms veneered > > I cut box joints for the tray sides. > I then biscuit joint the sides to the bottom. I place two sides in the vise at a time to create a more stable surface. > > Here is the lower tray assembled > and the upper tray which I tiled with 1” square mosaic glass tile> I th...
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