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"Most Challenging Piece?" from a comment on Derek's chair thread

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"Most Challenging Piece?" from a comment on Derek's chair thread

#1

Alan Young

Derek has been documenting his Dining room carver chairs in the thread below.  It's been fascinating to see the work progress. At the end of one Derek's late posts in the thread he asks Ellis and essentially all of us what has been our most challenging piece to build? I encourage everyone to dig through that thread to see Ellis's reply featuring a fabulous chair he designed in the 70's.  I am re-starting Derek's question re: "What has been your most challenging piece to build?" 
(Note: I have links to two pieces on my webpage in this post-when you click on the links you'll be taken straight to my page and must hit your browser "back button to get back to this post- I suggest right clicking the links and follow the open in new tab option)
 
I had to dig through my own portfolio and give it some thought. For me certainly that 80 inch Diameter Table I made a year ago is right there simply for the size of the entire project. But when I broke everything down to steps it became a long series of "do able" steps. So I think that Table project is probably no 2 on my list. For now I'm listing this Cherry Cabinet with  Stained Glass .   

My reasons for complexity:
1. This had to fit in a space with some quite spectacular furnishings, and feel "at home"
2. I had to build this piece without the stained glass panel available to build around. I am in Michigan and the clients are in Washington D.C.  There where dozens of phone calls/ and emails with the clients-I enjoyed working with them very much! But keeping track of all the details was a challenge even though the final piece was much less complicated over all than other pieces I've done or certainly other pieces they had in the same space. 
3. As far as making the door that held the stained glass panel-The panel set inside a rabbet on the inside of the door. But the panel was not square so I had to make the frame with enough "slop"  that I could place cherry shims in where needed when I arrived on sight. This also meant thinking of as many shapes as could bee needed and bringing as many tools as necessary to make the panel fit as well as apply any finish on sight. I did not take any pictures of the "fitting process" as I as too busy making the needed alterations. As I recall part of the process included rigging up a long straight edge to rout a taper on the door rabbet on sight that I had made nice and square back in my shop.  All turned out well in the end but I was sweating bullets in the processes.
4. One last memory- well there were actually many memories -including getting to see much of DC including the National Archives where my client worked, and getting to visit collage friends who had been living in DC for some time.,---but my wife and I made the trip in one long drive- we were schedule to arrive in time for dinner with the clients-spend the night at their home then set up and install the cabinet the next morning----in spite of cell phones and geo tracking I still managed to get us behind schedule for arriving in time for the dinner he had prepared. By the time we arrived it was probably two hours after schedule and I felt enormously awkward like I had made a pretty bad "1st impression".. Dinner was great though as was conversation between two couples that had nothing previously in common other than discussions about a cabinet design!

Re: "Most Challenging Piece?" from a comment on Derek's chair thread

#2

Two pieces come to mind. My workbench.........
IMG-0629.jpg
and my Stickley style bed (pictured prior to finish).......
IMG-0935.jpg

Re: "Most Challenging Piece?" from a comment on Derek's chair thread

Edited #3

Alan, your cabinet is spectacular, and the follow through in design elements brings it all together. That table is just another level!

Regards from Auckland

Derek

Added later 04 min:

Roger, I have long-admired your bench. It looks far too clean, however!  :)  

I made a similar bed, and I recognise the complexity in the glue up ... all those staves are such a fiddle to set in their mortises at the same time!

Regards from Auckland

Derek

Added later 10 min 22 s:

I'll add a couple of pieces here  .... I can say "couple" because most of the pieces I make are a stretch for my skill set going in. 

This seemingly simple chest of drawers, nicknamed the "Lingerie Chest" by my wife, features a bow front and tapered sides ...

FWW_on_Instagram.jpg

The drawers were really tough as the dovetailing at the front involved compounds ...

Lingerie-Chest.jpg

The top drawer has a hidden lock as it opens up into a jewellery drawer with sliding trays ...

Lingerie_Chest2.jpg

And the top of the cabinet has another hiding place, a dressing table (with catches made by myself) ...

Lingerie_Chest3.jpg

Regards from Auckland

Derek

Re: "Most Challenging Piece?" from a comment on Derek's chair thread

#4

I've been presented with several design challenges that took a while.
First was an urn that was specified to hold three equal parts of the cremains so the parts could be held by three family members, but then reunited as those folks passed.  The deceased was a theater director, so my solution was a puzzle box of 3 that would separate or reunite in a particular order in cherry and walnut, but reference a stage set.
Urn-Walkabout-2.jpg

Next was my son's request for a copy of a Green & Green storage bench piece they saw copied in a magazine.  It had to fit into a particular spot in their entry way.
Done in cherry with a darkening stain.  As it had to work as a storage bench in a house with a pair of  5 yo twin boys, elements in the original had to change.
Bandini-Delivered-1-1.jpg

Re: "Most Challenging Piece?" from a comment on Derek's chair thread

Edited #6

Derek.......you are correct about the difficulty of assembling all those slats (spindles......whatever you might call them).......I did that part of the bed dry......no glue.....just started placing a slat into its mortises at one end of the sub-assembly and then working more in place as I went down the piece......I used a clamp to keep things organized......and as I went, used another clamp to replace the first clamp.....and continued that way leapfrogging the clamps......those mortises and tenons were tight......so it held together.......and I keep my sanity......

Re: "Most Challenging Piece?" from a comment on Derek's chair thread

Edited #7

Peter Martin

The portable workbench I designed. Just add some weight to the top, nudge any corner, and it immediately folds into a pile of sticks on the floor for easy transport.
37-7_img_6452444c1e17f_375.jpg

Re: "Most Challenging Piece?" from a comment on Derek's chair thread

#8
Peter Martin wrote:

The portable workbench I designed. Just add some weight to the top, nudge any corner, and it immediately folds into a pile of sticks on the floor for easy transport.
37-7_img_6452444c1e17f_375.jpg

Interesting joinery there, Peter.  Style is, um, "Early Apocalypse" perhaps?

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