Neil’s Origins Table – Viewer Project
This mind boggling project comes to us from Neil. Its an incredible lesson in “outside the box” thinking! Let’s hear from Neil:
I’m a South African living in Britain watching your American show – interesting how the world works huh? I’d like to enter a Viewer Project: my “ORIGINS” table. I really want to share this project with woodworkers because it has proven that I have to, like you say, think out of the box. Our schooling and everyday life causes the thought process to become rather closed and problem-oriented, rather than free-flowing and conceptual. It is like nothing I have tried before. Even after three months of making I still wonder how it all came to be.
It began about a year ago with an idea I had for a cabinet. My wife was pregnant and the whole process of birth become a fascination. The idea of male/female, yin-yang, parent and child etc, which I hope is evident in the design grew into the idea of using not only opposing woods, but opposing shapes, textures, types of board/timber. And then the cabinet wanted to become a table that supported a “child” if you will – the bowl in the middle.
Now what I have to keep reminding myself here is that I was trying my UTMOST best to NOT think about how I was going to make it. I’m sure us woodies are all cursed with this, but it has become so important (like with David Marks’ and furnitology’s) to concentrate on design and the “mindset” of the piece first, then problem-solve the issue of “how?” I made 2 HUGE mistakes and almost gave up but decided to go on. I was already on a tight budget for it (the veneers for the top alone cost something like $150!!) but I decided that once you pop, you can’t stop.
I found myself using tools I never had before: a round-bottomed spokeshave to finesse the curves, soil and dirt to tarnish the copper, sawdust and cyanoacrylate glue as wood-filler, a round-bottomed surform to finish the base. I had an idea of what I wanted it to look like, but it was make-it-up-as-you-go-along all the time and that was such a refreshing (though often frustrating) change. I strongly believe now that it’s not what you know, but rather what you want to learn that counts, and as long as woodworking is respective of the beauty that lies in wood, it will always be good :) It’s the ultimate material and unlike other things, it grows on trees!
Here are some construction details: “Female” consists of 27 layers of 19mm birch plywood – each piece individually routed round and then glued and pressed together. The final shape was eventually achieved after much use of a surform, belt sander, chisels and LOADS of 80 grit sandpaper wrapped around a 1.5 inch dowel.
Male consists of two halves. Each is two layers of 5mm bendyply veneered with walnut using contact adhesive (I was worried this would throw the shape out but the 2 layers of bendyply seemed to work well :) Making this was the most difficult part as the two halves had to be joined in a straight line, down a shape that curves in two directions and not only in the middle but where it joins the female too !! It took days of trial and error with a block plane to get that edge down the middle ! It’s still not perfect but hey we all have our limits :) I first made the structure then veneered one side at a time. The compound mitre on the base of the male proved to be challenging too since it does not lie flat on one surface but on an edge.
The cherry piece joining the two was made from a single length for continuity and just cut into smaller angled pieces to achieve the curve. The “foot” that joins the base of the male was done by hand with some chisels and a belt sander. The bowl also came to be using bendyply. Veneers are Maple, Walnut and I think Burr elm.
Once I got the male and female to join nicely with the cherry, and the bowl all fitted, I started on the top. I routed a 3foot diameter piece of 19mm ply and edged it with a 4mm cherry strip. I achieved this using strap-clamps and very straight-grained quarter sawn cherry to avoid it splitting/snapping (Yikes!). Initially it was to be more of a yin-yang shape on top but the waterdrop shape of the bowl called for a more refined curve. I first laid the burr walnut veneer, then the burr cluster maple (quite pink isn’t it?) then I routed the groove for the cherry inlay.
The cherry inlay isn’t conventionally liad. Rather than a thin slice of veneer it consists of about 10 layers of cherry veneer laid on edge within the groove! That proved to be a rather testing time :) After some hand-planing with a SHARP edge, it was flush to the veneer surfaces. I recessed the glass supports into the top and made the template for the glass by tracing on a piece of paper with a pencil (similar to the copper method). I sent it off to the glass-makers and they did a swell job. The glass lid is lifted out using the inch hole.
Now the copper came by accident due to the fact that I had to cover ugly screws sticking out of the female where I had screwed the ply pieces together. I tried to remove them neatly but it turned ugly after a while :) So I decided – as a friend once told me – rather make a display of your mistakes than try to hide them. I think I have realized now how helpful that can be. So I drilled the three 65mm holes 3mm deep around the screws, got hold of some 3mm copper plate and after making a rough paper template I ground them out and shaped them using a belt-sander on edge with 40 grit paper. I then tarnished them by leaving them outside on the lawn for a few nights and beat and scraped them in any way possible to create the aged look. I glued them in with PU glue and sanded them with 600 grit.
The finish: After much debate and much research (including the help of The Wood Whisperer) I finally came to a conclusion. Danish Oil is one of the easiest finishes you could ever apply (I hope Marc agrees here) I have done lots of spraying and used varnishes and oils of all shapes and sizes, but since I had been laid off at work, I had no access to the spray-shop and thus needed a really easy no fuss finish. And I must say – it does take a good 4 coats over 4 days to do the job but it is ever so easy to wipe on. A rub down with steel wool between coats and then some good-old-fashioned beeswax (2 coats) and some elbow-grease to bring out a bit of a shine and I am really very pleased with the finish. I did want to use a polyurethane spray but I think it actually worked out better this way since I can rest assured it is easily re-finished or restored.
Lastly I must say that it really has been an amazing learning experience and I would not have been able to do it without the advice and general positivity of online shows like TWW – so thanks Marc and friends!
Natural Looking Bartop Finish? – Viewer Question
This week’s question comes from Doug. He writes:
“I am building a bar top from 8/4 Walnut for my son’s new home, and he wants to have a very natural finish on it – no film finish allowed. My first thought was to use BLO, but some research has led me to think that Pure Tung Oil might provide better protection. Is Pure Tung Oil a better option than BLO for an open grained wood like Walnut?”
And here was my reply:
Hello Doug Sounds like one beautiful bartop!! When it comes to protection, BLO and pure tung oil are pretty similar. One thing they have in common is that neither one offers a great deal of protection. If you had to choose, I would say to go for the BLO, since the pure tung oil will take longer to cure. BLO does have a tendency to “yellow” a wood over time, but that is a non-issue with walnut.
Now obviously your son is the boss here. But indulge me while I make a small suggestion. I can totally understand why he doesn’t want a film finish. I can’t stand the way they layer those thick finishes on bar tops. They should have just used something made of plastic, instead of wood. But there is a compromise between the plastic look, and the natural (unprotected) look. Just to clarify, BLO will certainly be better than nothing at all. But for a bartop, your son might regret this decision after the first few spills.
So my suggestion would be to try to achieve the best of both worlds. Give the bar top a very natural-looking finish, while imparting a great deal more protection than an oil alone. There are a few products on the market today that contain oil and varnish together, like Watco Danish Oil. Because there is so much oil in the mix, you would have to put on about 5 or 6 coats before you really start to get an appreciable film. But applying 2-3 coats will give you a really nice and natural look, while protecting the surface with a little varnish at the same time. And if you go with matte or satin formulas, I think your son will be even happier with the results. The great part about it is, you can look at the surface after each coat and determine whether or not you want to add another. Dilute the mix with mineral spirits if you want even more control. And also keep in mind you can simply make your own oil/varnish blend by mixing 1/3 mineral spirits, 1/3 BLO, and 1/3 polyurethane.
Either way, make sure you sand lightly between coats to keep the finish nice and smooth. After the final coat, either sand with 1200 grit paper or buff with 0000 steel wool. The wood will not only look natural, but will easily repel the occasional spill.
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