Won't You Sit and Stay A While?

There is a new piece taking shape in the shop, a Nakashema and shaker style inspired bench. The progress has been s-l-o-w, hampered by a lot of starts and stops. However, it’s progress and I, have much time to sit and think along the way.

The bench seat preparation has taken a lot longer than I had originally estimated. So to get you caught up… I glued two pieces of mesquite together to create the bench seat then broke out the trusty router plane and planed it flat. Note to self… I really need to get a bigger planer (isn't Dad's Day coming up soon?). After it was more or less flat, I filled the giant crack and numerous smaller ones with black tinted resin. Then more flattening because someone is really messy when pouring resin and that stuff does not just wipe off. 

My thoughts on the crack(s) in the mesquite seat. First, I’m not concerned about it from a structural standpoint, the resin more than takes care of that. In choosing to use mesquite, I am forced in most cases to work around them or with them. I personally love the look, the color, the depth of the grain and the overall richness of the wood. In addition, I’m fond of the organic and rustic nature of the wood. Since I’m choosing to use mesquite and since the tree grows very slowly and it’s rare to find one this big around without any cracks I’m forced to address them. My options are to choose a different wood species, hack several boards apart and then glue them back together (which I never really like especially in this case) or I can just let the wood be what it is, great looking - dare I say beautiful with some imperfections and character.

OK enough about the that.

I’m now working on the legs. Where the seat and back rest rail will be in mesquite; the legs and back spindles will be in white oak.  My hope, and what I’m planning on, is that the white oak will complement the lighter color sap wood of the mesquite and create a very nice balance. My fear is that the two different woods are going to be in stark contrast with one another. We won’t really know until the finish goes on so – fingers crossed.

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She's got legs...

I left you in my last post with cutting mortises for butterfly joints and they are FINALLY cut, cleaned and itching to find their home stitched in the table. My breath is held... will everything fit? Lots of parts and no tolerance for error (insert wide-eyed emoji). But in the end, pieced perfection.

Phew.

Now time for permanent, pieced perfection. Glue time.

I would consider myself a leg guy. For the table, y'all. Three legs or four? Straight or splayed? Dimensions? Shape? I struggle here as creativity can run wild, but just because you can doesn’t mean you should. Basically, I desire to turn a leg with interesting curves but must restrain myself. The beauty of this piece is the organic shape, the ripple of the grain and the cluster of butterfly joints giving rebirth to a simple slab. Adding unnecessary detail to the legs would only distract from that. A simple, straightforward leg with a slight splay and a delicate taper... I think this table's made for walking as I skip to the lathe.

After turning the legs, I drill angled holes in the bottom of the tabletop for the legs to attach. The angle creates the splay effect, which gives the piece a graceful, poised aesthetic and feel.

Sand and repeat. Finish coat and repeat (times five).

I’m often asked “how long does something like that take?” Here is my best guesstimate...

• 30 minutes loading/unloading and hauling the piece of wood home
• 2 hours to cut the piece to size
• 2+ years of drying time
• 5 hours flattening
• 1 hour cutting the ten butterfly keys
• 3-1/2 hours cutting the mortises
• 1 hour dry fitting the piece together (most of that was taking it back apart)
• ½ hour gluing
• ½ hour drilling stepped mortise holes for the legs
• 2-1/2 hours turning the three legs
• ½ hour test fitting and gluing the legs
• 3 hours sanding
• 1-1/2 hours finishing
• The tree grew for 67 years and I’ve been practicing, playing and learning for more than 30 years.

99 years.

I’m guessing that was not the answer you were expecting. So not counting the years of growing, drying and playing time, I have 21-1/2 hours of actual creation time with a piece that will last a lifetime.

In search of a caring home.

Patience

I’m beginning a new piece and thought you might like to follow along on the progress thus far…

Our story begins two years ago.

I drove past a massive pecan “log” waiting on the curb for bulk trash pickup. After enlisting the help of a friend, who also conveniently owned a truck, we liberated it from the landfill and forever changed its fate. The ride home was no small task, the piece pictured here originally weighed over 200 pounds. After drying for the last two years, its moisture content is below eight percent and it now weighs closer to 75 pounds (phew). When I curb-picked this piece, it was one solid stump but as it dried it began to check and split, eventually into three separate pieces.

My first task in creating a new piece is balancing the act of deciding what to create with the organic wonder of what the wood wishes to become. In this case, we both agreed on the obvious… it’d look damn good as a coffee table. The second task is to flatten the slab which is more commonly referred to as a cookie in the woodworking community. It’s always hard for me to say that with a straight face and not think of a furry blue muppet... but I digress... as the flattening creates a lot of crumbs. 

When you don’t have a tool that you need, in this case a planer that will handle the 40” width of the piece, you resourcefully build one. Hence my new router sled. This is basically a jig for the router that allows me to guide it back and forth over the wood and level or flatten it. While time consuming, you should see my muscular forearms.

During this process, I discovered that a section of the tree grew around and had a love affair with a chain-link fence... gotta love urban forestry. This required an intense focus during the router movement as I didn't intend to ruin my bit. Alas, when you lose concentration and run into said chain-link fence, there are sparks and flying segments of your carbide-tipped router bit that require a necessary, yet aww shucks, trip to my toy store (errr) Woodcraft. Moral of the story woodworking and metal working don’t mix.

After the piece is flat and the top and bottom are parallel, the intricacy of cutting butterfly keys begins that stitch the three pieces of the slab together. I’m always asked what those joints are called. They are referred to by multiple names: butterfly joints, bowties, keys, Dutchmen and the list goes on... my sentiment is butterflies.

I decide on three different butterfly sizes made from white oak, align their placement and trace each location on the slab with a marking knife. Then simple chopping the waste away with a mallet and chisel until the grooves are like butter. Sure, I made that part sound so much more simple than it actually is, but notwithstanding the years of practice, cuts, mistakes and blood.

So as I leave you, I am adding wings to butterfly joints and smoothing their mortises, while pondering the shape and detail of the legs.

Project 42 - John Hancock + Santa

Well it has begun… Santa’s workshop officially got into the full swing of production this past week. First up, a series of pens turned from a variety of different woods. These are only a few examples and there are many more to come, but I’m excited to present these as gifts. I even purchased a new Santa hat to wear while working in the shop and queued up a rather lengthy play list stacked full of Christmas tunes (Santa, baby on repeat). The only thing missing is the snowdrift on the shop window sill, but personally I think I'm a bit more productive with warmer weather.

The Micek household is choked full of holiday spirit this season. The lights are up outside and the tree shopping is slated for next weekend. We have already watched Frosty the Snowman twice and it is the front runner for this year’s favorite holiday movie/TV show (at least as far as the seven-year-old is concerned)... I'm shocked that Elf has moved into second position. We thankfully avoided Black Friday and weekend shopping, trying to commit to the true nature of the season. Yes, there will be presents under the tree but the best, most sentimental gifts are in our hearts. It is the moments with friends and family that matter, not the stuff.

So back to the shop as I have a list longer than my arm that I just can’t wait to create for friends and family. I’m sure that I will run out of time before I get to everything, but I’m so jolly tickled to be making almost all of my Christmas gifts this year. They are from the hand and the heart in the spirit of giving and the season.

Ho Ho Ho

Project 41 - Hey, Mister Postman!

Let me begin by saying thank you for all of the encouragement I received over the past week. It truly is amazing to have such supportive friends that always have your back. As far as how to proceed with the challenge, I’m going to take the suggestion of simply picking back up where I left off.

This week’s project has been a long time in the making, eleven weeks to be exact. Two mailboxes for a commercial building in the Bishop Arts District. I’m uncertain where they have been collecting their mail, but appreciate the patience and faith in me. I must also tip my hat to two other extremely talented individuals as one created the metal work and the other laser cut numbers. Despite the simplicity of the design, there is a tremendous amount of planning that goes into the construction and assembly process to create minimalism.

In addition to the design, I love the romance of their function. They allow people to connect with each other in a tangible way. In a day and age where we spend so much time in a virtual world, it still touches me to receive or send a letter on actual paper with rich, real ink. My favorite writing instrument is a fountain pen. The way the ink flows and dries on paper is magical. And call me crazy, but it makes me happy licking an envelope and stamp knowing the letter is almost on its way.

This has been a good project to ease me back into the shop. For this piece, it is far less about creativity and much more about math, mechanics and precision. I am really pleased with the end product and teamwork design. It is strong and will withstand the day to day use and abuse without being overly constructed or bulky.

Oh how I’m looking forward to my mornings in the shop again as it sets the tone for my day. I love the smell of the wood, the problem solving, the creativity and that I’m crafting something. There is also a renewed feeling that anything is possible.

“Everyone you meet is doing the exact same thing you are: trying their best to live through a day they’ve never been to before. Give some damn grace.”

Project 40 - Hello Again

Hello again. I’ve been away for a while, eleven weeks in fact. Life had thrown me a curve ball and well, things just got out of control and all tops-turvy. To be completely honest I’ve been pretty uninspired and unmotivated over the past couple of months. But hopefully that’s all behind me now. I’m back out in the shop and creating again.

As far as my challenge goes… Well, I’m not exactly sure how that is going to pan out. There is no way I’ll be able to finish twelve new pieces in two weeks to make my fifty-two-week deadline. So exactly how I finish I’m not sure yet, but I am going to finish. I’ll get that all sorted out this week and let you know.

So these past eleven weeks I’ve been working on sorting out - life. Well, I don’t know that I figured life out but my head is back on straight again. However, in the meantime, when I felt like it, I worked on updating my chop saw station. It might not be the sexiest or most creative piece I’ve built, but it is, if nothing else, functional. Before beginning my challenge, I constructed the basic framing for the stand. It supported the saw but was left unfinished and without reaching my initial vision. During my time "away" I boxed in the base and added doors and drawers.

I’m looking forward to using the new and improved miter station. It’s not perfect from an appearance standpoint as I did not spend time fussing with fancy joinery or in hiding exposed edges, after all its shop furniture.  But it is perfect where it counts. Its dead flat, its sturdy and completely functional. 

As far as life goes… Here is what I know. In the end it’s amazing, every day is a gift, it’s filled with highs and lows, ups and downs, but in the end it’s what you make of it. It is the sum of your choices and experiences.

“If you are depressed, you are living in the past. If you are anxious, you are living in the future. If you are at peace, you are living in the present.”

Week 39 - What does the GOAT say?

This week’s project is a departure from my traditional work, carved goat skull. Yeah... sounds so manly.  RAWWRRRR!

Continue reading if you want a little insight into its creation. I tried not to get too graphic, but reader beware.  

Let me begin at the beginning. A few months ago my lovely wife returns home from a trip to the farm with a bag full of goat skulls, horns and a few miscellaneous bones, mostly all still attached to one another. Needless to say the aroma was, well, not even something febreeze could mask. I know because she tried. OK, even though I’m so very tempted to describe the sight and smell in immense detail I’ll refrain. You can thank me when you see me.

So a long story short the first step in beginning this week’s project is to clean, sanitize and remove any straggling fur. Yes, you guessed it a big pot of boiling hydrogen peroxide and water. Add the skulls and bones, boil for an hour and half and voila... bleached, pristine, white skulls. The whole time this is happening I’m thinking to myself, “self, I wonder what my neighbors would think if they caught a glimpse of me now”. Every movie scene where someone needs to get rid of a body goes through my mind. And the bubbles oh so many bubbles. All in a t-shirt and boxers.

Now that the skulls are cleaned and several days have passed, I can stomach going back into the shop again. Creation is a messy and sometimes smelly affair, but nonetheless, I decided on a design and sketched it onto the skull. I used a Dremel, which is a tool similar to a dentist drill, and a variety of different bits along with a steady hand. Several mornings later you have the above. For my first attempt, I’m actually really proud of how this has turned out. I learned that goat skull is really thin and the crispness of the design would pop in a thicker skull.  

Hmmm... deer season is just around the corner.

Week 38 - Man(Shop)scaping

I'm finally starting to get and feel a little caught up in the shop. This past week’s project might seem a little unconventional and definitely not sexy, but necessary all the same. I spent last week cleaning up the shop and maintaining the myriad of things that call for my attention. It appears you can’t go this long and hard without doing some maintenance. It actually took me three mornings just to put away all of the tools that seem to have found their way onto every flat surface in the shop. Along with getting tools put back in their home, the drill press, air conditioner and compressor are now fixed. Almost everything with an edge is sharp once again except… I forgot the kitchen knives. Sorry babes (I was supposed to sharpen those when I was sharpening everything else. oops. Fingers crossed she won't read this one).  

Now that the shop is somewhat clean, I'm looking forward to spending some time over the next couple of weeks focused on a few shop improvements. There is a rather long list of items I've been meaning and wanting to tackle. All of this in preparation for doing a few personal projects and gearing up for Christmas gift creation. Ho Ho Ho. Wow it’s really hot outside to even think that. I’m still firmly in the summer state of mind, but if I don’t start soon it’s going to be too late. Above is a sneak peek into this Santa’s Workshop and if you look closely there is small hint to next week’s project that is in the works.

“Clutter is simply delayed decisions.”

Week 37 - The Apprentice

As you might have guessed, I'm behind in getting my projects posted. Too many things happening in the Micek household. I've been lucky enough to get the projects completed, but sharing the blog has posed some difficulty. So... here is last week's project. 

This past week I was able to finally complete a project that has been consuming the shop both in space as well as time and effort. Three conference table tops constructed from white oak in a chevron pattern are now in their new home. They rest on a steel base that was built by another amazing craftsman, and this past Sunday I was able to see the two halves come together. The tops will have a whitewashed stain and finish applied. I might be a little premature in considering these complete but I'm so excited in how they came out I just had to share.

The table tops have been physically the largest thing to come out of my little workshop. They look pretty simple but there is an inordinate amount of work and precision that went into their construction. They measure 6' x 10' exactly and are composed of two halves, which allows for a metal channel in the center to accommodate and conceal electrical cords. 

I was up against a deadline to get these completed and was lucky enough to have the help of an amazing assistant. Our daughter, Stella June, joined me in the shop to help glue and sand the tops. I really could not have have done it without her help. OK, things might have gone a little quicker, but I could not resist her sense of wonder and desire to help. She's a fantastic apprentice and it warms my heart that she loves to join her dad and dust out in the shop. She gets so jazzed and always seems to have a great sense of humble pride in her accomplishments and/or assists.  

"There is a girl, she stole my heart, and she calls me daddy."

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Week 36 - Spinning

Something a little on the lighter side for this weeks project especially after the last couple of week's. A toy top made from walnut and turned on the lathe. So simple but so much fun as well. I think I needed something just this simple along with some down time to recover. It's lighthearted and brings me back to the simplicity of my childhood. I can watch the spinning top for what seems like hours just getting lost in the whirl.  

In addition to this week's little project I had the honor of making the urn for Memommie, Callie's grandmother. I have a personal connection with everything that I make as there is a little bit of me that goes into every piece. However, in this case there was more, much more. Constructing Memommie's urn was beyond emotional and those hours spent in the shop were magical for me. So please excuse me for not posting photos of it, I'll keep those in my heart.  

"You are not going to master your life in just one day. Just relax. Master the day. Then just keep doing that every day."

The quote reminds me to take each day as it comes. To do my best in the moment and to live life to the fullest. Sometimes, especially after a great loss it's hard to do that but the ones we've lost would have wanted us to live. To truly live.