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On Saturday afternoon the Washington Campaign Desk project officially became a completed piece of furniture when I moved it from our downstairs family room into our “office”. In actuality, the construction of the project was completed two weeks ago and the finish applied over the course of a week. While I’m very much an amateur when it comes to finishing, and I may have already mentioned it in another post, I will briefly touch on the topic again.
In most cases I would have finished walnut with BLO and some wax. I wanted to go with something more refined, and after some online research I wound up with a product from Rockler called ‘Sam Maloof poly oil/poly wax’. The instructions were similar to other finishes: sand to 400g, burnish with 0000 steel wool and a soft cotton cloth, apply liberally, and immediately wipe off the excess with a soft cloth. (I’m glad they added the immediately, because letting the finish sit is a recipe for disaster no matter what anybody, anywhere will tell you). Anyway, the recommended sequence was 3 to 4 coats of the poly/oil blend, and 1-2 coats of the wax blend, with a 24 hour drying time in between coats. I went with 3 coats of the poly/oil, and 2 coats of the poly/wax, and I can say without any reservation that it was the easiest and nicest finish I’ve ever applied. Even better, it is dead simple to apply further coats in the future for renewal purposes. At $20 per pint it was not inexpensive, but in my opinion it was well worth the cost.
I have two regrets with this project: One, I wish that I had documented the little details a bit more. Two, I would have done a better job on the through dovetails at the back of the drawers. Don’t get me wrong, the drawers are square and tight, but compared to the rest of the desk, I think the through dovetails are a bit sloppy. Speaking of the drawers, I did not fully assemble (meaning glue them together) and finish them until after the final coat of finish was applied to the desk itself, just in case some final resizing needed to be done. And the last task, adding felt bottoms to the drawers, was completed yesterday.
I felt a great sense of accomplishment when we moved the desk into our office. I added some of my memorabilia to it and it really brought the desk to life. Everything looked like it belonged, and when I replace the oil lamp with a real candle lantern I believe it will look even better.
This desk was the first full-sized piece of furniture I built this year, and more significantly, it could be the last full-sized piece I make in a long time. Not that I’m planning on giving up woodworking, but the real truth is I have very little room in my house for more furniture. Currently, the living areas of my house contain 14 pieces of furniture I built. That is a respectable number. So from now into the foreseeable future, I will likely be making small boxes and such, which I am fine with, because whatever else happens, I built something that I am extremely proud of, and I set the bar higher. Now, I just need to find a suitable chair…
‘But those who hope in the Lord will renew their strength. They will soar on wings like eagles; they will run and not grow weary; they will walk and not faint.’
One of the things that has always bothered me concerning woodworking forums, magazines, etc. has been an overemphasis on the spiritual/metaphysical aspects of making furniture. If there is one quality that I despise in anybody, it is an overabundance of self-importance. A lot of people, too many people, tend to over-value themselves, and the things they make, in relation to how they think others should perceive it. I had mentioned in an earlier post a trip to Mount Vernon and how that trip was in many ways a spiritual experience for me. Others may visit Mount Vernon just because they enjoy the grounds, and others still may visit and feel nothing at all. So when it comes to the Washington Campaign Desk I recently completed, I am very much in the mindset that it is without a doubt my favorite project, yet I would not doubt that some may look at it and think to themselves: ‘big deal!’
Firstly, as far as woodworking projects go, this desk, for someone at my skill level, would probably be considered an intermediate level project. For a professional woodworker it would likely be considered a relatively simple build. It was not the most technically difficult project I’ve made. In fact, I can say in all honesty that I spent as much time milling the wood and cleaning up the resulting mess as I did on the actual woodworking involved in constructing the desk. One of the most time consuming individual aspects of the project was making and fitting the breadboard ends, and when I carelessly removed a chunk of the desktop with a shoulder plane I wound up removing the ends completely rather than attempt a shoddy repair. If the two plus hours I spent on the breadboard ends are removed from the equation, I probably have more time spent milling than woodworking.
As in all of my projects, I like to think that I become a little better woodworker and learn a little bit more every time I complete one. But I cannot assign any one particular “Eureka” moment when it came to the physical act of working the wood used in making this desk. Probably the most challenging aspect of the construction was sawing and shaping the ogee ends. At that, the job I did was just okay. I certainly learned something, and I certainly gained some experience, but I don’t feel any closer to the woodworking gods in doing so.
After re-reading these few paragraphs you might thing that I sound bitter, or even ungrateful. Rest assured, I am neither. As I said, this project is hands down my favorite, and it is possible that I may never build anything again that I like quite as much. Why? It is simple, really. I went to a museum and caught a brief glimpse of a piece of furniture that was likely used by a person who has very much guided me throughout my life, and I knew enough about woodworking to be able to construct a near-enough reproduction of that piece of furniture using only a memory and a photo. If there is any “spirituality” to be found, this is it. When I saw the desk I knew immediately that I had to make it. I experienced a unique moment of true inspiration. I wasn’t looking for it; it wasn’t forced; it just happened. And in my estimation, that is the essence of spirituality.
There is more of me in that desk than in any other piece of furniture I’ve made. It isn’t in the joinery, which is dadoes, bolts, and a few screws. It isn’t in the desktop, which quite frankly has a bit more “character” than I had hoped, or the drawers, which are made of basic home center poplar held together with some basic half-blind dovetails. It is something that can’t be seen by others, and I’m glad of that fact.
I could write ten more pages trying to explain my reasonings, but I’m not going to do that. Just know that when I look at that desk, I feel connected to something larger than myself. And I believe that when I finally use it, I will be inspired to be my best.
I don’t know if there is a “woodworking god” or not. But if there is, just for a brief moment as this desk was nearing completion, I believe that I saw His face
For all intents and purposes I completed the construction phase of the Washington Campaign Desk over the weekend. On paper there wasn’t much left to do. Basically I had to assemble the drawer compartment parts and attach it to the desk top. But we all know that “on paper” doesn’t mean much.
Assembling the drawer compartment wasn’t overly difficult. I pre-drilled and counter-sunk the screw holes, applied a little glue, and screwed it together. That part was relatively easy. I had one minor issue, and that was the right side drawer divider would, for some reason, not sit perpendicular to the desk top. I double and triple checked the dado fit and no matter what I did I could not get it perfectly straight. Don’t get me wrong, it is not off much, probably 1 mm or so (for all you metric people), so I decided to not let it bother me. To finish it off I used walnut plugs purchased from Rockler; they worked surprisingly well, and I’m very happy with the finished appearance.
In the meanwhile, I also pre-drilled and counter sunk the holes in the desk top to attach it to the leg assemblies (using elongated holes to allow for movement). But before I went any further I disassembled the base and spent a good 90 minutes with a hand plane and sandpaper cleaning the parts up for finish. As far as the sanding was concerned, I used the grit sequence 60/120/220/320. I did not use a random orbit sander, rather, I just used a sanding block because it seemed easier to control, though it was definitely more time consuming. Once the sanding was finished I reassembled the legs, and thankfully I marked all of the parts before I took them apart to assure that I would put them back together correctly. I used a little glue to attach the filler pieces to the leg cleats, but otherwise, the only glue used in the entire project was on the four dadoes on the drawer compartment, and the walnut plugs. (I promise once it is finished, with finish, I will photograph all of the relevant parts). With the leg assemblies ready to go, I attached them to the desktop and reattached the cross cleat, once again plugging the countersunk holes and cleaning them up.
The last part of the assembly for me was the scariest, and that was attaching the drawer unit to the desktop. Before I took everything apart I marked and predrilled holes into the desktop. To attach the drawer unit I decided to use pocket-hole screws. I like using pocket-hole screws in situations like this because of the pan head holds nicely on elongated holes. In any case, I used two combination squares (I highly recommend having two BTW) to align the drawer unit, enlisted my lovely wife to hold the drawer unit in place, and carefully screwed the drawer unit to the desk top. Speaking for myself, it’s always a bit nerve wracking lying on my back and screwing through a tabletop sight unseen. Thankfully, everything went well.
And speaking of pocket screws, I may attach a cleat underneath the desktop to connect the two leg assemblies, just for added strength, because as of right now they are only connected by one cross brace. After doing some research it appears that pocket screws were traditionally used for such a task, believe it or not, but as of right now I still haven’t made up my mind.
The last task of the day was milling up some poplar for making the drawers. The drawer fronts were completed last week, but I didn’t want to plane them to final size until the drawer unit was assembled. I decided to go with half-blind dovetails for the drawers, which is the logical choice. So I gang sawed all four drawer sides at once, tails first obviously. I am holding off on the drawer backs just to make sure there is no settling, or what have you, before I glue the drawers together, but that part should only take a matter of minutes.
As far as the finish is concerned, when I started the project I spent some time searching the forums to find a nice finish for Walnut and kept coming back to a product called Sam Maloof poly/oil. It seemed to get good reviews, so I ordered a can of both the poly/oil and the poly/wax. The instructions call for 3 to 4 coats of the oil and 1 to 2 coats of the wax, with an overnight dry in between each application. I likely won’t start applying the finish until this coming Friday night, when I will have time to take my time.
And on another note, I am not overly concerned with the finish when it comes down to it. I used to worry a great deal about having a perfectly smooth, plastic-like appearance. But considering that the boards used to make this desk likely came from barn walls, I am more than happy with how it looks. I was more concerned with doing the best job I could do, and I believe that I did that. The desk looks like I want it to look, and I believe that it is well constructed and it should last for quite a while. I think that George Washington would have liked it, and more importantly, my daughter loves it, and I have a feeling that she will be the one to use it most, and that is about all I could ask.
This past weekend I began the scary phase of every one of my woodworking projects, and that is the time when there are a lot of almost finished, unassembled parts lying around waiting to be destroyed.
First things first, on Saturday afternoon/evening I spent two hours milling up the final two boards needed to complete the project. Well, it was about an hour milling up and an hour cleaning up. Rather than calling it a night, I wanted to get in a little actual woodworking, so I attached the cross brace to the back legs. I did not want to mortise out the legs because they are thin to begin with, so instead I dadoed the brace, 3/8 of an inch, planed it down, chamfered the edges, and sanded it smooth. I was satisfied with the appearance, so I attached it with some decorative brass screws. Thankfully, it added some much needed stability to the legs. Admittedly it took longer than it should have to lay out the dadoes, but I wanted the fit to be dead accurate, and I really didn’t want to waste a perfectly good board just by being careless.
Overnight Saturday we had a wind storm, so I spent a portion of the morning and early afternoon cleaning up the back yard, which really ate up the prime hours of the day. But I soldiered on and decided to get as much of the drawer unit finished as possible.
I took my sweet time with those dadoes, because I only had one crack at it, and once the kerfs were all sawn I used a chisel and router plane to get to finished depth. The fit was nice, so I moved on to what I believe is the most challenging part of this project, the ogees on the drawer compartment sides.
Considering that nearly all of the furniture I’ve built to date has been in the Arts & Crafts style (as well as some Shaker pieces), laying out and sawing an ogee with a coping saw is not my strong suit, but I decided to give it a try regardless. I used a compass and my limited artistic ability to lay out the ogee on one of the drawer unit ends, clamped both together, and started sawing. The results were mixed; I should have stuck closer to the line, but in the end it was done. Afterwards, I spent a good hour using a spoke shave, chisel, and rasp to get the pieces in shape. In the end, I wound up with more of a sloping cove than a true ogee, but I am not unhappy with it, and once it is sanded down I think it will look pretty good.
The last task of the day was adding rabbets to the side pieces of the drawer unit, which I did with a moving fillister plane. I could have pushed it and fitted the drawer dividers as well, but that part should be simple, and I didn’t want to push it, as it was getting late and I had a lot of clean up to do.
After clean up, I once again brought all of the parts into my family room for safe keeping. I attached the “ogeed” ends to the drawer unit top and placed it on top of the desk. I liked the open appearance, so I think what I may do is leave the space in between the two drawers without a back, just to see how it looks. If I don’t like it, I will simply add the filler piece, but I think that open area may add some lightness to the desk, and I could always bore out a space for an inkwell cup there.
Happily, so far none of the pieces have been damaged in any way. By the end of next week the desk should be ready for finish, as the only thing really left to do is make the drawers along with finishing up some light sanding. I’m hoping that my lovely wife steps in and does the finishing for me, as she is much more patient than I am when it comes to stuff like this. Otherwise, I am in the home stretch. And for those of you who celebrate the holiday, have a Happy Thanksgiving.
My favorite part of any furniture project is the point when a solution has been found to a challenge. It’s a figurative crossing of the “hump” which then signifies hopefully smooth sailing moving forward. This past Saturday I crossed that hump.
The bad news first. The temperatures in the area dropped well below freezing, and though that is not unheard of in my neck of the woods, it is uncommon for this time of year. So after I returned home from work on Saturday the first thing I did was check on the desk top panel. The panel is just fine, but the breadboard end with the issue was not looking so good. The underside developed a split that was instantly noticeable. Maybe the cold exaggerated it, but at that point I didn’t care, so the instant decision was made to saw off both of those bread board ends, which I did using the table saw and a cross-cut sled. I understood it meant losing a few hours of work, but I know the decision was the correct one because I felt no real remorse then or now, and rather than dwelling on it, I moved on to putting together the leg assemblies.
The leg assemblies posed a bit of a challenge, at least to me they did. Firstly, I wanted them to appear as if they could fold up, so I could not ship lap them together, though that in some ways may have been easier. The dilemma was attaching them to the cross cleats, which sounds simple but was a bit complicated.
The issue was the offset of the legs. Because the legs were not ship-lapped, one side of the leg would obviously offset, in this case ¾ of an inch. So my solution was to make a filler board to make up the gap made by the offset. At that, I wanted the board to match the angles and width of the cleat board as closely as possible, so I spent a good deal of time clamping and measuring. Once I was as sure of myself as I was going to get, I made the cuts, planed it to final size and started drilling holes for the quarter inch hardware I purchased for the project. I won’t lie, those first couple of holes were nerve-wracking, because a mistake would cost me several more hours of work, but once I got moving things went relatively smoothly. It took more than two hours, but in the end I had a finished leg assembly.
Sunday morning I started on the second assembly, and using lessons learned from the previous night’s experience, I had it finished and ready to attach in under an hour, so rather than leaving those two assemblies on top of the workbench, I did just that attached them to the desktop using some angle brackets. I hadn’t planned to do an assembly to be honest, but curiosity got the best of me. The good news is that so far it looks pretty good. Admittedly, I was a little disappointed that the breadboard ends needed to be removed, but it doesn’t look bad in my opinion. But the better news is the fact that the legs all sit level with the ground. Generally, when making a table, there is usually a bit of wobble. As of right now the table sits nicely, and when I placed a level on the top I found it dead flat. At that, the table does rock a bit back and forth, but considering it is not permanently attached to the top yet, and considering the leg assemblies haven’t been joined together yet with any cross bracing, that was to be expected.
Lastly, I removed the assembled table from my garage and placed it in the family room, where I think it will be much safer. Over the years, I’ve found out the hard way that leaving unassembled furniture projects in my garage is a recipe for disaster. Maybe it’s gremlins; I don’t know, but whatever it is my projects seem to take a beating if they sit in the garage for too long, so I was taking absolutely no chances. In any event, the cat seems to like it, because as soon as I brought it inside the house she promptly hopped onto it, sprawled out, and took a nap.
Next weekend I will mill down another board to use for the cross bracing as well as the desktop drawer unit. Thankfully, I already have the drawer unit finalized in my mind, so the construction should have no unwanted surprises. So with a little luck I could quite possibly have a desk ready for finish a week from now.
On another note, some of you (or none of you) may be wondering why I did not post last week. Well, I had the very good fortune to go to Washington DC and not only take a tour of the White House, but to visit Mount Vernon as well. The Mount Vernon trip was not planned, it just happened to fall into place, and because I had not been able to go there last time I was in DC, I made it a priority. I will only say of the trip that I was completely blown away. The furniture examples in Mount Vernon alone are beyond description, and I would have taken photos, but they are not allowed inside the house itself. And because I believe that rules are a good thing (they are hardly “for fools” as some in the woodworking world would claim) I did not attempt any, and instead purchased a very nice book with photos that are much better than those I would have taken anyway.
My family, who was skeptical about the Mount Vernon visit in part because the day was cool, cloudy, and damp, was nonetheless blown away. My daughter in particular was completely awestruck. But the highlight, for all of us, was visiting the final resting place of George and Martha Washington and paying our respects. When I say that this trip was beyond inspirational and much more of a spiritual experience, I am understating to the highest degree. Upon leaving Mount Vernon, my admiration of George Washington, which was already immense, grew even greater. And more than ever I am committed to making this desk to the highest level I possibly can.
I started and completed phase 3 of the Washington Campaign Desk project on Sunday afternoon, but I ran into a few problems, one minor, two a bit more concerning.
As I mentioned in prior posts, when I began this project I decided to build the top with a breadboard end detail. The reason for going with breadboard ends was not only for added stability, but also for appearance.
I’ve seen breadboard ends made in several different styles, from one long tenon, to a ‘haunch’ style tenon, to dowels. I decided on the one long tenon (1 ¼”) for no particular reason other than it seemed to fit. The process for creating the joint went smoothly enough, though it was somewhat time consuming. I set up the table saw with a dado stack, made several test cuts to center the groove, and proceeded to make the groove, raising the blade height ¼” on each pass. Once that was finished I did the same for the tenon on the desk top.
The first issue, and to my mind the biggest, came when I was cleaning up the tenon. I used a shoulder plane to do the bulk of the work, and that worked well, but a slip of the hand left a nice little ding on the front left corner, which would not have made a difference had I not decided to go with breadboard ends. Unfortunately, when I was doing a test fit I noticed the gap that the ding made, around 3 inches long and 1/16th of an inch wide, which doesn’t sound like much until you compare it with the rest of the joint, which is pretty much right on the money.
The second issue, and to me almost as troubling as the ding, came when I installed the dowels.
I used 3/8” oak dowels to hold the joint in place, and I decided to drawbore the joint for added security. I’m not overly experienced in the art of drawboring, but I’ve done it enough to not be afraid of it. Drawboring, briefly and in layman’s terms for those of you who may not know how a drawbored joint works, is when you drill out the hole of your tenon slightly closer to the shoulder than the holes bored out on the breadboard ends. This, in theory, will pull the joint closed very snugly and help to eliminate any gaps between the shoulder of the desktop and the breadboard ends. To leave out the dull details, it worked just fine in 5 of the 6 holes. On the last joint (as usual) the dowel pin I used went crooked, which is a sure sign that it needed to be tapered more. So I took a nail set and used it to tap out the pin, and of course it blew out a very small but noticeable chunk of the wood on the breadboard piece. Under other circumstance it wouldn’t have bothered me in the least, but because this piece is right next to the dowel, which is oak and much lighter in color than walnut, that little ding looks huge. I of course glued the blowout back in, but I have no idea how it is going to look until everything is completely sanded down and ready for finish.
The “minor” issue, and the easiest one to fix, is nonetheless the most disappointing to me. After all of the work, I’m not exactly sure that I like how the breadboard ends look. It’s an easy situation to remedy; I can just saw off the ends and in the process I would only be losing around 4 inches of desk top length (along with several hours of work and effort). I can easily chamfer or round over the top for a pleasing appearance. So I trimmed the breadboard ends flush (almost) and gave the top a light sanding and I’m still on the fence. I won’t lie, the dings are bothering me, and one showed up inexplicably near the center of the panel; don’t ask me how as nothing was dropped on it, but stuff like this seems to happen in my garage.
The center ding should easily be fixed with an iron, but that gap is not as simple. One option is to make up a filler with some glue and sawdust, the other is to just hide it with the drawer compartment. A third option, as I said, is removing the breadboard ends completely. I wanted the gappy area to serve as the front of the desk, because I like the grain pattern there and also because the other panel has two knots with some really funky stuff happening.
My plan now is to fix the dings as best I can, and then adding a coat of sanding sealer to see what I am working with. Otherwise, any advice would be much appreciated.
This past Sunday afternoon I began day 2 of the Washington Campaign Desk project. The main objective was to get the legs sawn to finish length and width along with the cleats to attach it to the desk top, the secondary objective was to get the desk top planed flat. If everything was working at optimal level I even considered getting the rabbets cut for the breadboard ends. Happily, I at least got the first two items on the list checked off.
To start, on Friday night I got the desktop sawn to final size (minus the breadboards) 40 inches. I then ripped one of the boards I had prepped last week into 4 strips, 2 ¾ inches wide and 6 ft long. Those boards were to be used for the breadboard ends and the 4 legs. So on Sunday afternoon I first chose the nicest board and cut that to the rough lengths needed for the breadboard ends. I then got to work on the legs.
The legs turned into a bit of a challenge. Cutting the angles was not really much of an issue as I simply used the cardboard template I made, but working around some of the knot holes and defects was a bit more difficult, or at the least time consuming. I basically hemmed and hawed for 15 minutes trying to lay out the cuts in such a way as to utilize the best parts of the boards, and then I got to sawing with the table saw.
The table saw work went quickly; after a few test cuts to set the angle of the legs, I had them sawn to length along with the cleats in a matter of minutes. But there was a minor drawback; in choosing the best aspects of the boards, I was forced to shorten the overall height of the desk from 29 inches to just over 28 inches, which I can certainly live with, in particular if that is the worst thing that happens during this project.
After the legs were sawn to length, I ripped them to just over their final width: 2 ¼ inches, as I will use a hand plane to finish them.. I then did a few test layouts using the template and so far everything looks good. Once that was all finished I turned to the desk top, where I discovered a minor issue.
When I glued up the two boards to make the desktop I wanted to remove any of the sapwood that I could, and I thought that I had. But at the seem there is a very fine line of sapwood that I honestly hadn’t noticed. Initially I thought it was just a bit of glue that had seeped through when the boards were clamped, unfortunately I was wrong. But, I am not going to worry about it. These boards are old and have a lot of “character”, so going in I knew that I was not going to end up with a French Polish level of refinement. But I did get the top planed to where I wanted it, using the jack plane and smooth plane. On that note, in cases like this I use the jack plane very much like a smooth plane to take fine shavings. The Walnut planed nicely, and I can live with the results.
Before I called it a day I gave the underside a quick plane as well. As I had mentioned in the prior post, the glue up went smoothly, so the panel was nearly flat to begin with, and really only needed some touch up work. While I had the desktop flipped over I added some epoxy to a knot that had developed a small crack, just in case. Lastly, I got to cleaning up the garage. It wasn’t too late, so I probably could have made an attempt at the breadboard ends, but I didn’t want to push the matter; I’m in no rush.
Next weekend, my goal is to complete the breadboard ends, and quite possibly assemble the base. If I manage to get the breadboard ends finished I will give the entire top a quick once over with a plane and possibly start sanding. Once I do that I can get to work on the base assembly. Initially I was a little worried about the base, but I figured out a very simple method to attach the legs accurately that should allow me to get to the fun part: the desk top cubby.