Asheville Coffee Table

Asheville Coffee Table

A client came to me for a coffee table and told be they could not find what they were looking for and wanted to have it made.   They wanted it to be 20 x 30 inches with bronze colored metal banding around the perimeter.  They also wanted the wood to be on the darker side but still have a natural look to it.   Per my request they sent me a couple pictures of what they had in mind. 

After some discussion I took their example and came up with a design in an elliptical form.  For their approval I made a prototype out of mdf and plywood in the proportions they wanted.  

After the client approved the prototype I began my search to acquire the wood and steel.   The walnut came from GPS Hardwoods in Kernersville, NC.

Glenn from GPS Hardwoods explained that this batch of walnut came from western NC near the Asheville area.  Glenn has his own kiln and acquires his own logs to mill and kiln dry.  Glenn allowed me to pick through and select the wood I needed.

To acquire steel for this project I searched through area metal recycle yards before I found the 3/8s steel needed for the legs and later the 14 ga sheet for the banding.  

 Shaping the legs

Shaping the legs

I cut out each leg individually with a grinder and cut off wheels.  I then performed further shaping, with grinding wheels, sanders and files.  Next I had to shape the outside banding by making and using templates of various radiuses to accommodate for the metal spring back.  

 Preparing the components for dry fit.

Preparing the components for dry fit.

Once all the pieces where formed it was time to put it together in a dry fit before applying the patina and chemical bronzing agent to the steel.  Then after welding everything in place a final sanding of the tops was needed before applying the initial lacquer coats to the walnut.

Getting the metal patina to the desired color took several coats of Japanese brown by applying a sprayed chemical to each piece.  This was done with the metal cold and then later applied with the metal heated to around 200 degrees.  In between these stages I did some light sanding and blow torching additional spray.

In the home stretch, time to finish tack welds, weld over the screws and grind to appropriate look.

 Finished product ready to show the client

Finished product ready to show the client

 In the clients home it's new setting.

In the clients home it's new setting.

Mid Century Modern - Contemporary Twin Platform Bed

Mid Century Modern - Contemporary Twin Platform Bed

An ederly client is moving to smaller quarters and desired a twin platform bed.  She also wanted to in corporate her existing full size headboard into the new bed.  

 Remove Trim from existing headboard

Remove Trim from existing headboard

 Resize the headboard

Resize the headboard

 Make a base frame for the platform

Make a base frame for the platform

 Making the top of the platform

Making the top of the platform

 Install the legs

Install the legs

 Apply finish

Apply finish

 Headboard installed and ready for disassembly and packaging for delivery

Headboard installed and ready for disassembly and packaging for delivery

 Delivered to client a couple days before her moving to new accommodations

Delivered to client a couple days before her moving to new accommodations

Steampunk Side Table

Steampunk Side Table

From farm to table:   My latest creation which I just finished this past week, was centered around a  massive piece of rusted iron that was a "barn find".  I was allowed the opportunity to go into old barns on a farm designated to soon become a housing development.   The iron was found under some debris in one of the barns that was still partly standing.   

 Getting the rust off took a couple days with a belt sander,  a grinder with flap disks and finally a dremel to get into tight areas.  After derusting and polishing a metal blackener was used to give contrast.

Getting the rust off took a couple days with a belt sander,  a grinder with flap disks and finally a dremel to get into tight areas.  After derusting and polishing a metal blackener was used to give contrast.

The vision I had almost immediately, was to make this into a vintage/space themed table.  My version of steampunk.  The base would resemble a rockets bottom section, topped off by a two tier top that resembles a flying saucer.  Overall it should have a steampunk feel to it.  

For the top I used some antique oak and walnut that I had previously retrieved from an abandoned farm house in central NC.   The land owner said it had been rough cut and stored in the house since the 70s'.  To put it all together I shaped some walnut supports for the two-tier tops. My thought was the bottom tier as a place to put remotes, phones, tablets or even a small laptop.  All tucked safely away and pretty much out of sight.

     Worm holes were filled with epoxy, highly sanded, routed edges, then all lacquered

    Worm holes were filled with epoxy, highly sanded, routed edges, then all lacquered

The based is curved walnut legs below a round sub base of oak and walnut.   

 Legs are put together with floating tendons and fastened to the sub-base.  The iron is lag screwed to the base and the top.  

Legs are put together with floating tendons and fastened to the sub-base.  The iron is lag screwed to the base and the top.  

The finished product.  Next is to shoot some promotional photos once we determine a location.

The finished side table is a one of a kind, never to be duplicated new antique.  This is for sale just contact Pops. 

We're up on the new website!

We're up on the new website!

We're up and running on the new website.  Many thanks to my daughter Devin for helping get some cool pics taken of my bench.   Now with some old pics I had on hand, we're on the way to web stardom.   Well maybe not stardom, but I am looking forward to making new creations and showing them off here.