Re: Order? (log)
Henry (Raleigh NC)
I love your design questions Bill - your q and the responses to this thread have already been thought provoking.
Design and learning new techniques are the aspects of ww-ing that keep me engaged and challenged; I doubt I would ever make a second piece ‘just like that’. If only I had the skills and experience you exhibit so clearly doing case work, I'd have a few more pieces under my belt. But in fact I am not as productive as you are, IN PART because I am fairly often trying something new (lots of other reasons too).
This is a long post – includes a few examples, as well as what I realize is my evolving process of design.
I'd challenge your order of function, engineering, aesthetics.
I start with aesthetics.
My 'process' starts with sketches, as described earlier by Ellis and Richard (and others): a bunch of sketches that might explore aspect ratios, or thicker legs, or tapers, or changes in the base or support structure, or new door/drawer layouts. I do consider how I would construct/assemble these as I draw, so I do have difficulty with the really 'creative'/wild/unusual/art pieces (but then I am doubt that you necessarily are desiring to go to art pieces either, because where would the socks go?
). I am really mostly concerned about aesthetics FIRST - the overall look and style.
I often go from a sketch showing overall form and structure to deciding on critical dimensions - as determined by function (table height, or fit into the space), or other constraints (available materials, etc). Many other design decisions are made or re-made on the fly.
So far no one has mentioned mock ups, but this has proven to be an essential aspect for me. Generally these are full sized pieces, but with construction lumber base/legs and cardboard tops (or re-purposed old paneling), with a lot of screws holding it together. Placed in the desired space, a mock-up has been a great confirmation that the piece is sized correctly (or not) and that the general aesthetic works (or needs modifications). Granted a mock-up is easier to use when the final placement is less than 100’ from the shop, rather than across the country. Vision is important here – as a crude table base with a 1/8” old paneling top is not a great check on aesthetics (because I wanted a 2” thick top); thankfully my wife can envision to a great extent, and trusts my judgement (in this arena at least). Using that specific mock-up we changed the table base of a bar height table to incorporate stretchers that worked as foot rests (while seated, not standing).
For me mock-ups work great for
1. sizing pieces – is this table large enough or small enough? – and placing a piece of cardboard or paneling at the right height and living with it (using it?) for a few days tells you quickly whether the size or shape will work.
2. Scale and proportion – overall, but especially leg size and thickness; also stretchers.
3. Placement (i.e. stretchers height)
Back to design on the fly - an example of this for me is the splay and taper of a leg. I can’t bother making precise sketches or CAD drawings for that level of detail. I can decide with real sized pieces in the shop. For me, often working with reclaimed materials, the constraints of material size and condition can influence such design choices.
Engineering is my final choice, although it has not been ignored up to this point. Looking at a sketch I typically have a joinery plan. Knowing that M&T is my go to, rather than dovetails (I have mostly made tables, not case pieces), I can examine the overall sketch and decide precisely how pieces will be joined. With loose tenon joinery, I can cut pieces to desired lengths (or longer) and layout real pieces to decide on actual part dimensions (eyeballing; i.e. rip that down to 5/4 thickness and change the taper to a ¾ square base rather than a 1” square. Make a test piece and a decision; an improvement? Yes? Let’s go with that).
Note that there is a definite trade-off in my approach. Because I don’t have ‘everything’ decided ahead of time, shop time is not always ‘productive’ in the sense of making stuff; some sessions involve considering and pondering design. This may not appeal to some, but to me that is the fun part of making custom furniture. When I construct for others, there is far less on-the-fly designing.
I want to add that for me available material also has design influences. 2 examples:
1. I have made a bar height kitchen table that has a single piece table top (24” wide x about 70” long).



Some design choices were made at the lumber yard when I found a stack of 4/4 of padauk boards that were 24-30” wide, with lengths of 7-15’ (best of all their winter sale had no premium prices for wider boards! Still I have never paid that much for a single board, about $10/BF). I picked out one was the right width (27” +) and length (80”?) that would allow me to glue up the thickness of the edge to make a 2” thick top (in appearance at least) using the extra width and length.
I realize that Bill’s choice is not to choose exotic lumber (or veneer?), but my design choice was in fact to do so; I wanted a somewhat showy and unique table top. I found a piece that was the look of what I wanted (without being to specify exactly what I was looking for), and being able to buy this one piece of paduak beat the heck out of trying to learn veneering for this piece.
I’m not opposed to learning skills; in fact I often choose projects that incorporate some element or technique that I have not done previously.
2. The maple headboard and mahogany framed bed that I recently posted here on WC is a second example.

I knew the overall design parameters: a frame and panel headboard with a curved top. I had the mahogany (reclaimed door pieces) and wanted a contrasting panel for the headboard. Once I found the 14” wide mineral stained maple board, I knew it would become the visual focal point of the bed. I chose the size and curvature of the headboard to work with the lines in the maple.
So maybe your struggle with aesthetics is because you leave it to last. You (Bill) are an clearly an experienced and productive woodworker – but I am guessing that your desire for shop efficiency and productive processes does in fact get in the way of the ‘design and aesthetics’ process. To me at least, once I accepted that inefficiency into my making process, I was able to be more creative. This is NOT a formula, but does describe my experience.
One final thought – with a parallel to finishing. Early on many woodworkers think they are almost done once the piece has been constructed. Those of us with more build experience generally acknowledge that finishing is simply ‘the third half’ of the process. I think design is the same thing – I often spend as much time and consideration in the design phase (not creating the build plan or cut list, the proportion and aesthetic choices), as actual construction. In part this is because I like this; it is not one long sit-down session, for me designs happen over days/months/ or years. Once I acknowledge and accept that this can be a long process, it is easier to live in that process for the time needed.
Henry