|Project by KnotCurser||posted 01-16-2010 01:08 AM||6501 views||2 times favorited||5 comments|
This was done for a client late last summer. He had heard I had a supply of walnut and one of the pieces was fairly massive and nicely grained and wondered out loud if it would make a nice mantel shelf. “Sure!” said I!
The piece was so massive in fact that I had to cut it down to fit in my planer – I had enough left over to make the corbels out of and a few more longer pieces I’m planning on using as legs on a future table.
Seeing how heavy this is and the dimensions of 13” Wide x 63” Long and a little over 2.5” Thick, I kind of KNEW I wouldn’t be able to just “freehand” this beast through my portable bench planer! I just had to make a sled – and not just any sled either – the mother of all sleds! :-) It had to take 70+ pounds of wood on either side of it and be rock solid the entire time. Also would help if it were a little slick as the poor rollers in my planer needed all the help they could get! ;-) I found some shelving at Lowe’s pre-wrapped with melamine – the perfect size and the perfect slickness at a great price! This worked perfectly! As you can see it gave me great results!
The shape of the corbels were finally agreed upon and cut out of the reminder of the stock and also turned out very nice – I’m really happy with the shape and smoothness of them – reminds me of marble.
All the pieces were treated with around 5 coats of Danish Oil with sanding between each coat.
Well, the client finally saw the piece when it was all finished and was flabbergasted! Didn’t know what to say for nearly a minute and finally managed a muffled “Wow”. I guess he was impressed. ;-)
As soon as he gets the proper supports installed to hand the thing, I’ll post a pic of the finished mantel on the wall.
-- Robert Rhoades WoodWorks / Email: email@example.com / www.rhoadesclan.com