|Project by Mark Kornell||posted 09-16-2016 05:32 AM||1208 views||10 times favorited||12 comments|
‘Round about this past Easter, daughter #1 asks if I can make her and her husband matching nightstands. Sure, I say.
There’s a bit of a.logistical issue, tho. They live about 1600 miles away. We try to visit every summer, so if they can wait, we can bring nightstands to them. OK, they’re cool with that.
Wasn’t too hard to come with a modern design they (and we all agree “they” actually means “she” :-) liked. Fairly simple cabinet with 2 drawers and small open cavity.
I’ve been pretty busy in the shop this summer with paying gigs, so this project kept being pushed to the back. That is, until 3 days before we were due to leave. I’d finally cleared out my schedule and needed to get busy with the nightstands. Managed to bang these out in a hurry and apply the finish. Last coat was sprayed on at 1:30 a.m. the day we left.
Being in a hurry, I didn’t take any build pics. But I have a SketchUp model I will post when we get back home.
Made one change on the fly in day 2 of the build when I realised that we’d never be able to fit 2 assembled nightstands in our car and have room left over for luggage. Instead, I built them to be transported flat and assembled at the destination. (Yeah, sort of like IKEA. Only I use solid wood.)
Much fretting over this on the way. Didn’t have time to check to see if every fit together properly before we left. Didn’t know if the drawer boxes were the exact width needed to work within the tolerances of the slides. Didn’t know how the ultra-fresh finish was going to deal with bumping round for 1600 miles.
Got to the destination and just about everything fit perfectly. And the finish held up impressively. Only one problem, related to switching to a flat-pack transportation approach. I had to add screw blocks under the shelf instead of cutting a dado and glueing the shelf. As a result, the screw blocks interfered with the top drawer box. Fortunately, son-in-law has a buddy with a table saw, and I was able to cut the box down to fit.
The entire piece is made from hard maple, excepting the drawer boxes made from Baltic birch plywood. Drawers are a 6 piece construction – 5 piece box with an applied front. For transport, it comes apart into 2 sides, a top, a shelf, a.bottom and a back. Stacks about 6” high.
With the drawers, seems to weigh about 60 pounds each. Noticeably heavier than a 50-lb bag of.concrete.
Finish was WD Lockwood #163 dye (Weathered Oak) followed by Varathane Nano Defense. I will repeat how impressed I am by how the finish held up during transport. We packed and stacked the pieces less than 7 hrs after the final coat of spray, and then let them jostle around for 3 days. No scratches. No pressure imprints. Hard to sand between coats, tho. Just eats sandpaper.
Anyways, the kids like the nightstands, which is pretty much the point of making them. :-)
(Edit: Here is the link to the model: https://3dwarehouse.sketchup.com/model.html?id=e965bca6-0a36-4da5-8c5a-fa123bdf79f3 . The model does not contain the mid-build changes to allow flat transport.)
-- Mark Kornell, Kornell Wood Design