Quick interruption. I have set this website up in chronological order. If you’d rather jump to the latest posts, please use the archive links to the right.
My introduction to woodworking was watching Norm Abram on the New Yankee Workshop and Roy Underhill on the Woodwright Shop on my local public TV station. At the time I was also watching This Old House (when Bob Vila was still on). Even though I did grow up around construction (grandfather was a carpenter, father was an electrician), I went in a different direction until much later in life.
Like most everything else I’ve been curious about, I was very academic (read nerdy) in how I pursued woodworking. Before I purchased any tool or lumber, I read about furniture making and woodworking in general. I followed Norm, Bob, and Roy and then through them, I learned of other woodworkers and scoured the Internet for content. I picked up on Tom Fidgen, Paul Sellers, Elia Bizzarri, Curtis Buchanon and many others. I lurked on dozens of woodworking forums, watched videos and bought books until I was ready to start buying tools.
My favorite hand plane.
I loved my job in IT but knew I needed something to take the edge off after a tough day/week/month, so as I chose my first tools I already knew that I would be primarily unplugged as my intent was to have a quiet (as opposed to the loud datacenter) and relaxing introduction to my new hobby. That said, I did follow the recommendations of a few online and fitted my shop with a 14-inch bandsaw, a 12-inch planer (thicknesser) and a benchtop mortiser and drill press. Of those power tools, the only one I really ended up using on a regular basis was the bandsaw (and to a much lesser extent, the planer).
This blog is about the path I’ve taken as a woodworker. I’ll talk about projects, books, videos, pretty much anything related to woodworking.
We’re currently living near Edinburgh, Scotland where I am attending the Chippendale International School of Furniture, something that my wife and I had been planning for a while. This has been a dream come true for me and I’ve been drinking from the firehose since class started. I’m enrolled in the professional course that includes the following:
Timber identification & timber technology Tool and Machinery induction Sharpening 3D/Perspective drawing The fundamentals of joinery Woodturning Cabinet Making Carcass construction How to make a dovetailed drawer & hang a cabinet door Restoration/conservation of antique furniture Steam bending & Laminating Veneering techniques Fretwork Marquetry & Parquetry Oyster & Boulle work Inlaying (Brass, Ivory & Mother of Pearl) Woodcarving Gilding Windsor chair making Leatherwork Finishing techniques (Oil, Wax, Shellac, Spray lacquer, Staining & Colour matching) Business skills, pricing & customer care Branding, PR & Marketing, and website development & management Machinery maintenance How to set up a workshop
I didn’t realize it at the time, but furniture restoration and repair are the most challenging, fulfilling and enjoyable activities related to woodworking that I’ve found so far. That doesn’t mean I won’t find something else along the way but for now…
The school is also a working business that does restorations and repairs and I was given the opportunity to fix a chair that was brought in. At first, I was quite a bit nervous that I would screw something up that was irreparable but with Graham and Clare’s wonderful tutelage I was able to take this project on. Graham and Clare are the school’s repair and restoration experts and it is a very common sight to see them working on pieces. We all know that all we have to do is ask and we can take part in any repairs or restoration that comes in.
The chair is mahogany, 19th or early 20th century. with banding and inlay on the back splat.
The front leg had been broken from the frame. The seat had been removed before it was brought in to the school.A 13cm section had come away from the front frame and was still attached to the leg. The tenon from the front frame into the leg had snapped.I was going to remove the frame section from the leg. Tried getting meths into the joint, but it did not loosen. After talking to Graham, I decided to leave it.
First thing I did was to remove the front frame to enable easier access to the damage.
First, I removed the screws for the corner blocks going into the back of the front portion of the frame.
I was then able to use spreader clamps to slowly separate the front portion of the frame. Mild pressure with the clamps and a rocking motion allowed me to free the front leg from the tenon. I wasn’t at all sure I’d be able to do this, but as soon as I heard the tiny ‘snap‘ I knew that the tenon had separated from the leg. I wasn’t positive that it was a clean separation, though, until more of the tenon was exposed.
The next step was to create a mortise into the portion of the frame where the tenon snapped and then to remove the broken portion of the tenon from the leg.
I will create a mortise where the tenon snapped.I’ll remove the broken tenon from this mortise.New mortise created in the frame.Mortise cleared out in the leg.New loose tenon in the frame made from matching mahogany.Shows the tenon being fit into the leg (the top of the picture).Showing the loose tenon fit in the leg.
After the loose tenon had been glued and set overnight, I fit the front section to the rest of the frame to see how the break would come together.
I fiddled with the fit and tried to get all of the torn pieces to slide into their respective places, but the broken piece was still just a wee bit proud. Rather than remove any more material, I decided that once I had blended the pieces together you wouldn’t be able to tell.
The next step was to go ahead and glue this up and let it set overnight. I then took a bit of scrap mahogany and fit it to the opening.
This took a while.
Next, I began colouring the new patch with water-based dies and sanded (exposed) old material to help blend.
I used Yellow, Van Dyke Brown, and Walnut.
I then put 3 coats of shellac (dewaxed) on and blended with the french polish mouse (3 swipes with the mouse over the repair and into the old part of the frame).
The next day I roughed it up to take the shine off. Used some pigments with shellac and coloured wax to blend in and fill the smaller areas. Then White Wax over the repaired area and buff.
One of the most valuable (to me) skills that my furniture making course has taught me is the core fundamentals of furniture restoration and repair. Graham and Clare, who are both as great at teaching as they are at repair and restoration, have allowed me to look over their shoulders (and incessantly ask questions) as they have worked on pieces. I have also been able to work on some of them myself, which has not only been a great and challenging experience but has been extremely fun as well.
Graham and Clare have both been with the Chippendale International School of Furniture for more than 2 decades and are easy to talk to and wonderful to work with on these great pieces of furniture.
The goal was to fill/replace the missing pieces and to make the repairs sympathetic to the age and blend them into the overall condition of the piece. If we decided to make the repairs perfectly flat and shiny with no gaps, then each repair would have stood out and looked out of place.
First thing was to lightly clean the areas that needed repair.
Each of these spaces was cleaned with scalpels, awls, and pretty much anything I could get my hands on that was small enough to get into the crevices and cracks. The bottoms of these spaces needed to be relatively smooth so when I fit the replacement pieces of wood in there they would sit flat and have a good stable glue surface.
More of the missing pieces.
The next step was to put tape over each of the empty spaces and lightly shade with a pencil to get the outline of the missing area.
After I had a good tracing of a missing piece, I put the tape on a piece of (in this case) walnut that I’d be using to patch with. I made sure to orient the grain with the existing veneer.
Anselm and Graham believe the table is from around 1760 and the veneer is several times thicker than any you can buy today, so the repair pieces were resawn on a bandsaw to be just a bit thicker than the old veneer. This way we could pare down the patches to the correct level.
Next, I cut out the pieces oversized and then fit them using small files, sandpaper, and scalpels.
This shows a couple of different stages. A couple of the spaces have been cleaned, one is ready to be traced, and one has a patch already fit (it still has tape on it).Another area ready for patching.And with some of the patches fit.
The next stages were to glue the pieces into their respective spots
Using a combination of tools to shave the patch down a bit.
Once the patches were in and the glue dried, I used a combination of water dies to get the patches to blend with the background. I then used coloured wax sticks and melted a mix of colours to fill and blend the repairs. (I don’t have pictures of these steps because once I got into it I was so engrossed that I forgot). Next was a light going over with some black wax, to blend all of the repairs with the rest of the table top.
As always, the repair and restoration is just a wonderful experience.
One of the first projects I’ve started working on since moving back to the US is a rocker I picked up at an antique shop. Normally, you don’t find a piece in this shape in an antique store, but it looked like someone wanted to have a go at it and then gave up. The caning had been removed and some of the paint (original dark red) had been removed, but other than that it was just in a sorry state.
Someone got started on this project but didn’t have the time or desire to finish it.A previous repair.
As I went over this piece, I noticed some things that I would change when I rebuilt it. An example is the rockers, which split along the grain in several places. I’ve decided not to try to reuse these rockers, as I did some experimenting with glue-ups and looked at all the holes created by other repairs and figured it wasn’t worth it.
Another thing I decided to change is how the seat was put together. There were two dowels holding the sides to the front and back pieces of the seat. The side pieces were curved and they split in the short grain.
These side pieces of the seat split along the short grain at the edge.A bit blurry, but you can see where it split through both dowel holes and then up through the top.
Other than that I didn’t see much that I wanted to change so I took the chair apart.
Once I had the chair apart (except for the top rail and the side piece that I think had been glued together with epoxy or similar) I stripped and cleaned the pieces so I could better evaluate each piece and the joinery.
This is when I found that the frame for the back caning had split into dozens of small pieces, so this will need to be replaced.
Next up in part 2 I make parts for a new seat frame.
So, my glacial progress on these first restoration and repair projects has been a bit disheartening, to say the least, but I’m within spitting distance of finishing the small oak dresser, so here we go.
This is the 2nd project in a group of about a dozen that I’ll be working on in between my day job and getting my workshop insulated (which I will write about in another post). It is an oak dresser that originally came with a mirror. The mirror may be in the group of mirrors that I received with these projects, but I have not tried pairing them yet. The dresser is likely early 1900s or, less likely, late 1800s. The drawer fronts and top are solid oak and the interior is in good shape. The casters are original wood wheel and brass and the drawer hardware appears to be original as well.
Serpentine front small oak dresser. It’s in pretty good shape except for some burns, water stains, and other discolouring.
The dresser was not in bad shape but required some work done to the damaged top, so I got out the card scrapers to remove the burns, then filled the shallow divots with shellac which I coloured to match the rest of the top. Some alcohol and a scrubber got out most of the rest. I then put a few coats of shellac and then some dark wax (Kingdom Restorations). Clare, a tutor at the Chippendale International School of Furniture used to say, “Dark wax can hide a plethora of sins.” In this case, it helps even the tone across the top.
I also needed to replace a damaged runner. This was the only “woodworking” needed for the project.
Damaged runner on the bottom.
I then cleaned out the corners of the panels of the frame and panel sides. This may seem like a nit-picky thing, but in this case, I wasn’t going for a heavily patinated look. Getting rid of the black gunk in the corners just sharpened the edges and “youngened” it up a bit.
I replaced the old casters with reproduction casters from Van Dykes Restorations. The new casters are beautifully made and all I needed to do was plug the old holes, then drill new holes for the new casters.
New caster wheels were just a wee bit larger than the old ones, but the larger wheels roll more smoothly over carpet or rugs. The new casters also have ball bearings – very nice.This picture shows a hole that has been plugged and is ready to be drilled for the new caster. This shows that on one of the back legs there was some separation between the different sections of the leg, so I used the glue squeeze out from the peg to put those back together.
While I was working on the casters I noticed that when they were making this dresser, they used a table saw or similar to cut the mortises for the side rails.
On this side you can see the kerf of the saw, so it looks like it took 2 passes to get the right width for this tenon.For the two top short drawers, the saw just went the entire length.
After this I noticed that the stiles for the side panels were starting to separate so I cleaned the old hide glue out and cooked up a few ounces to re glue.
The hardware was not in horrible shape but a few of the bail pulls were either missing rosettes or the rosettes were damaged so I searched E-Bay and found some nice ones and also found some that I liked at Van Dyke’s Restorers. Even though I found some knobs there as well, I decided to keep the original.
Old knobs and new pulls.
One thing I didn’t replace (yet) is the missing escutcheons for the two top drawers. Why, I can’t even begin to say, except that brain farts are real.
I just have a few fiddly bits to finish up like the escutcheons and runner blocks for the drawers to keep them from jamming, but other than that this has turned out to be a very pretty and usable piece of furniture.
Don’t look at the missing escutcheons!Before re gluing the sides.Top turned out beautifully. The cigarette burns and other stains came out very well. There is one divot that I didn’t fill because it was wide but shallow and I figured it was not very noticeable. If I had this to do over again, I might put the time into filling and colouring it, but probably not.
I’ll probably take a look at some brighter, shinier hardware for this one, but I doubt that I’ll go with it. I like the darker hardware on this. I will probably post some pictures with the brighter stuff though, just for comparison.
Just wanted to post a quick update on her foot surgery. The procedure was a success and she is already standing and using her new toe.
Before the operation.With her splint.
All the major repairs and restoration are now complete and I’m now working on the sides and some of the egg and dart moulding. Very close to being done.
Last post on this project as it is finished and ready to go back to its owners. Lots of before and after pictures, but you can find the entire process here.
Before…And after.
Replaced all of the hardware (locks, hinges, pulls, escutcheon).
