To keep with the Greene and Greene style theme, I decided that I wanted to use some black square pegs on the finger joints. Headed over to Rockler hoping to find a turning blank of Ebony, but the only things they had was Salt & Pepper sized and about $80. I ended up spying a piece of African Blackwood that was 1.5”x1.5”x6” that would work out perfectly.
Took it to the bandsaw and resawed a 1/4” wide piece off, and then sawed that piece up into 1/4”x1/4” strips.
From there, I chucked a block plane up in my vice, and passed the pieces over the plane a few times to clean up the bandsaw marks.
From there, I cut them into 1.5” long pieces
Since the pegs typically have rounded faces in G&G, I used a technique that I saw from a William NG video sometime last year.
Chuck the pieces up in a drill (or drill press in my case), and use a sanding pad backed by something soft like rags. I started at 80 grit and went all the way up to 320 grit. Then you square the sides a little bit by sanding a bit more with the 320 on each side.
Here’s what you are left with:
Almost polished faces on them. Each piece has both ends done in this way. Once I assemble the tray together, I’ll cut them to be about 3/8” long, as they are only decorative to cover up the dowels that will be used for strength.
I also decided to change up the design on the handles a bit. After looking at it more, I didn’t care for the cloud lift and couldn’t come up with an opening that looked good. So, I revised my design to this, which is still a design prevalent in G&G furniture:
Once that was finished, I set to laminating the veneer work to the plywood backing. I guess during the glue up the boards I was using for cauls weren’t putting enough pressure or weren’t flat enough because the glue up came out a bit wavy. When I tried to sand it down, it pulled some rope pieces off, sanded through in a few other places, and just looked absolutely horrible. I attempted to fix this by splicing in new pieces, but they stuck out quite a bit. There really wasn’t any way to make it look acceptable, so I decided to scrap the effort on this. The areas like the lettering looked fine (although a bit thin in the M), but any attempts at fixing just made everything worse.
Back to square one. This was about 10pm last night, and I decided to start again on a new background. Decided against the rope pattern since it didn’t turn out like I had wanted to, even the areas that did stay attached. By 1am, this is what I was left with:
Now I need to re-do the lettering, inlay that, glue everything up again (and correctly this time).
-- The quality of one's woodworking is directly related to the amount of flannel worn.