Bespoke Oak Framed Norwich City Shirt

Over the last few months I have been designing and making a 2" deep box frame to display a signed Norwich City football shirt. It has taken a few months to build because I was secretly making it for my mum, she had no idea! This meant I had no real deadline to meet. When I had other jobs to do this project kind of got pushed to the side for a while until I had some free time to work on it.

The idea was to make a deep, breathable frame for the shirt to hang freely inside. I wanted to make sure no condensation could build up on the inside of the frame as this would harm the shirt.

A little about the shirt.

My mum is a HUGE Norwich City fan. For her birthday last year she was given the shirt by a friend of hers who managed to get it signed by the complete premier league promotion winning squad. Her friend that got the shirt is a cousin of the Goal keeper. So this is a very special shirt and I felt it needed something interesting and eye catching to display it in.

This is what I came up with:

Following my signature style of work, I used my multiple changing cube design, hand cut and finished from solid pieces of oak. I cut a unique profile into the oak to hold the clear perspex into tightly so it cannot move, a 1 inch thick area for the shirt to hang freely inside of and a 3mm rebate for a backing board.

I used a 45 degree angle on the corners with a hidden spindle inside each joint for extra strength when gluing. I also chose to use a decorative joint called a butterfly key. These small keys lock both sides of the joint tightly to one another and stops them from separating while looking gorgeous.

I made an oak hanger for the shirt which was fixed from the inside to the top part of the frame.I also added a majority of small holes in the sides of the frame for air circulation so it could breathe easily.

The backing was also handmade using 3mm thick strips of oak which I run down in a table saw to the thickness required and made them into a panel to fit the frame.


I will share a few photos of the build from the first marking out to the finished piece:

This is what I started with, 4 pieces of oak I prepared to 60mm x 40mm. This is the unique profile marked out and ready for removal.

This image shows the profile cut out, the cube design cut into the oak and the 45 degree angle (no spindle).

A quick test fit for square and angle fitment. This image also shows the cube design quite well.

All the sides rubbed down and edges softened. The oak hanger location being marked out to the frame.

3mm oak backing board panel made and fitted to its place.

The glue up, clear perspex fitment and butterfly keys driven home.



The finished frame:

                                                          Finished with the shirt mounted, ready for display.




I am so happy with this frame. It is like nothing I've ever seen before. It easily draws your attention straight to it when you enter the room it is displayed in. There has been a lot of praise for this from everyone that has seen it. Pictures really don't do it justice!

It has also had offers made from Norwich City fans which I unfortunately had to turn down. This was a gift for my mum. It is currently hanging in the middle of her living room where it looks completely at home!

Solid Oak Chest

Things have been a little quiet from myself for a while unfortunately. Many things have accounted for this including a big shape up in my place of employment, mountians of extra work in said employment, a house move and general life. I am suprised at how quickly time has flown by! I am a little disappointed at myself for letting my oak work live on a back seat and leaving it there for so long.

That time has now come to an end. I am back in the zone and scribbling down ideas and designs I'm going to tackle next and it is a great feeling. Why I let it go for these past few months I do not know!

So about this Oak chest.

I have a good friend that does genuine medieval reenactment and he casually asked if I can make a chest for him to carry all his armour, as he uses a large hold all bag at the moment which is not very authentic. So I agreed I would make him a chest. I set about with a few drawings and joint ideas to which he swiftly said no to. He wanted a very strong square box with a lid sat on top, but... with no joints that could be seen.

I suggested maybe a hidden dovetail joint which is not very 15th century I know, but it will be very strong and not visible like he wants. Downside to this idea was the 45 degree angle which the dovetails are cut into which was not used back then. I went through all the basic box joinery with him and he stopped on a lap joint and wanted that, which was easy for me but not very strong at all. So I then suggested fitting dovetails into the lap joint creating a lapped hidden dovetail joint.

A bit complex but ideal for what he wanted. Very similar to the hidden dovetail but modified to fit into a lap joint. The dovetails get hidden from view once fitted tightly together and the box from above looks lap jointed.

If I have lost you with all these joints I apologise. A quick run through with picture of what I did.

I started with these lovely air dried boards.

I then ripped down the boards and hand finished the edges for a perfect join and glued them up.

After sanding smooth and cutting to size I then set about marking the lapped hidden dovetails.

An example of how the joint works once chiselled out.

Once everything was cut out, I made the chest base which was cut to size and lap jointed to the bottom of the 4 sides. Everything fitted nice and tight so out came the glue and clamps to glue everything up.

After checking the squareness I letting it all dry over night. The next day came the first coat of oil and making the lid. (sorry no pictures of the lid making)

After everything was complete and 3 coats of oil were applied the end result was this.

The lid was slightly wavy which you can see in the pictures and my friend loved it.

I finished this the day before he took it to his first event this year which was a close call to get it done in time.

The idea I last heard was he wants to fit leather straping for hinges and a buckle type fitting to secure the lid down. I think once the leather is fitted it will totally transform this already very beautiful chest into something very unique which is my ideal finish to a project.

One last thing to do before it is finished. I am trying my hand at wood burning and engraving as he would like his genuine family coat of arms embedded into this chest as it is made to last. This chest might well be passed on through the years which makes me even more proud to have made this.

I will be sure to update this as soon as progress is made to it.

My love of Danish oil

Danish oil is my preferred finish to all my work. This is because the transformation it brings to a piece.

The images below shows what amazing features that danish oil can bring out in the oak. This waney edged coffee table top had many features to show off even before the oil was applied to it, but coupled with the oil the results were outstanding.

With the oil rubbed in with a microfibre cloth, just one coat (there will be 5 in total) transformed the piece with patterns, colours and lines that were unseen until the oil was applied. The golden colour which the oil has also gives off a warm feeling from the furniture once it is completed.

 

The results of Danish oil still amaze me. I love it and it is a bonus that it is also so easy to use.

New custom coffee table.

I have been asked to make a coffee table for a colleauge. He picked out and supplied an oak beam to use for legs and rails and a lovely waney oak board with a large knot in it which will be an amazing feature to this table.

The oak beam provided to me needed to be cut up to use for the legs and the rails. I used a table saw to machine to beam down into 4 chunks at 75mm x 75mm. I planed two faces flat and square with each other and used these edges with the table saw to cut the other sides of the timber square. I then check everything using a tri square and everything was spot on. The legs were 68mm x 68mm finished size before cutting the design into them. I used the remainder of the oak beam to cut out the rails.

I worked with my colleauge to design the table to his liking. He was certain on the design of the leg as it was his own. Plain rails was what he wanted so no detail on those. I set out marking the mortice and tenons which is the fixing method I am using for the rails to the tops of the legs.

After a lot of mallet and chisel work the mortices were chopped out and the tenons fit nice, tightly and all square. I placed the table top on the constructed legs and rails to give an idea of what the coffee table will look like when it is finished. The height was perfect and my colleauge is over the moon with it. I have some sanding left to do, glue the rails and legs together, 4 x buttons to make to fix the top to the rails and a generous 5 coats of danish oil which will bring out the beautiful lines and markings of this piece. There are many, many medullary rays in this table. Finished images are soon to follow!

 

Oak beam bed frame finished!

 Following up from a post on the 29th December 2011 I am pleased to say that my oak beam bed frame is now completed! I have a few pictures to share of the build and a brief run through of what to picture are.

The 3 pictures you see above are what the oak was like before I began working on it. 150x150 beams and a 35mm thick waney edged board I found and used for a head board. In the last image one of the oak beams releaved some amazing medullary rays (silver grain) once it was sanded down.

The timber rails joining the foot frame of the bed to the head board frame were Ash in stead of Oak. I went for a change when I saw this was available to me and the grain patterns were unreal! I was glad I used this once I saw it. The foot end of the bed was sat on top of 300mm legs which were fixed using mortice and tenons. These were fitted tightly in place and an oak peg was used to hold the joint together.

The last image is to show the design of the bed and to test fit the joints which are mortice and tenons.

The head board joining was hand cut using a tounge and groove fixing method. Once the pegs were driven into the frame joints it pulled the frame tight together sandwiching the head board tightly in between the upright posts to make up the head board frame as seen in the second image of these three.

The last image is the bed frame joint work completed and fitted together. No pegs have been driven in yet so the frame can be taken apart to easy moving. The jobs left to do was to groove out the Ash rails to take for the mattress and pine bed slats. I used pine for a bit of give and flex for under the mattress.

I used 12 slats in total. Each one was 25mm x 100mm spanning the width of the bed frame. This easily supports the mattress with no sagging what so ever.

I gave the whole bed frame a danish oil finish to protect it and to bring out the beauty of the oak and ash.

Sleeping in the bed after getting it home was fantastic. It is as I wanted it to be. A solid, sturdy bed that looks different to anything else. The large beams dwarf everything else in the bedroom and makes a real presence in the room. No movement, no creaking from loose joints and no sleeping in a bog standard bed. Perfect!

From the 6 year dried oak beams to the finished bed frame was all hand made. All joints were worked out and cut by hand. The mortices were cut using a drill and chisels then everything knocked together using a rubber mallet. A belt sander and a drill were the only power tools I used for this whole build. Creating and making something by hand is extreamly rewarding. So happy with this!

Starting to bring things up together.

Over the last few months I have been trying to create my own basic logo and branding, so I can start building a visual name for my business to get the ball rolling.

As at this moment in time I am in full time employment which doesn't leave me much time in the day to work on my projects as well as use the internet to get traffic to my pages. I try cram as much into the day as I can. I am in the process of making and finishing four projects and I try to work on two of them each day. Maybe concentrating on one at a time will help get them finished and in my etsy shop.

Finishing more pieces will fill my shop that I can start getting potential customers to visit and see my work! Promoting my full shop rather than individual products will be easier I hope.

I think this blog needs a facelift as well and more people coming to it as I don't promote this as much as I should.

So the ball is starting to roll ... slowly. But this is just the start!

Solid oak?

The term Solid oak in furniture should be as it sounds... Solid.

But...

I keep finding myself looking at handmade furniture in shops which are listed as a solid oak table or solid oak chairs that are not solid oak. Solid in my mind is made using one whole solid piece of timber, not many strips glued together to form a thicker piece.

This one table I have in mind was listed as solid oak. It was a lovely looking kitchen table, pretty grain patterns, a strong 2" thick top, and straight chunky legs. Very nice. But it was not solid like it says it is. Upon closer inspection every section of it was strips glued together. The whole table and it was £1300. I was a little disappointed to be honest, which I keep finding myself when looking around at "solid" furniture.

Maybe it is just because I know I use fully solid timber for my work and maybe expect things to be the same.

Quality made products will far exceed products of "not so good" quality. If any of you are out and about, have a closer look if you are thinking about buying solid wood items. Maybe you are totally happy with these types are products and if so, Fantastic. But just keep an eye out for things that are not what they say they are.

Coat Rack

After only just noticing that me and my partner have an ever increasing pile of coats laid across the top of our shoe chest in our hallway I thought the time has come to make a coat rack. I wanted to make something quick, simple, different and interesting. It didn't take me long to cut and shape something out. I chose a dried 30mm thick oak board with an attractive grain pattern. I shaped the corners different from each other also for something unusual. This is what I came up with:

Once sanded smooth I decided on only oiling the raised face side of the oak and the outside edge. A clear wax coat for the rest of it. The idea being a darker warm coloured face sitting on a lighter back. As if the front has been fixed on after.

I had this finished and waiting to go for a good few weeks while trying to find some hooks to use with it. I didn't want to go for new, bright and shiny hooks in a light finish. I was more looking for old, patina, worn, dull. At the start I was thinking a distressed bronze but after seeing a few examples I thought the golden bronze would not suit the look I was going for.

So a darker finish was the way forward. Many charity shop visits and car boot sales later nothing seemed to appear.

I had a massive stroke of luck when speaking with my partners mum about the hooks. She had an old coat rack in the shed with hooks matching what I was trying to find.  They were perfect. I could finally finish this small project that I though would take maybe two days to make, find hooks and put up. It was more like 6 weeks.

I gave the hooks a little scrub in some warm soapy water and dried them off thoroughly before mounting them. I decided on placing the hooks unevenly again for something different. And finally the finished project (before fixing to the wall) photographed by my partner Louise. (See her blog here http://www.dearestjackdaw.com/ )

Bench refresh.

I was asked by my partners Gran to take a look at her garden bench as she was worried about it collapsing if someone sat on it. Sure enough it wouldn't have taken much for it to collapse under a little weight. The bench itself had two cast iron ends with wooden slats bolted to each of the ends. The slats were rotting at the bolts which meant it was not very safe at all. On top of this many of the slats had been replaced before, but only with softwood.

So I obviously said I would sort it out for her. I didn't want to have it collapse with her sitting on it one day very soon. I showed her what the problem was with it and she gave me permission to do what I wanted.

I had no doubt that Oak would have looked great with the black cast iron ends.

We were invited up for a lovely roast dinner at the weekend so I thought I would get the bench done while we were there and this is the result:

Looking fresh, bright and new. It has made a massive difference to the overall appearance and strength using Oak. I used new stainless steel dome headed bolts and used a wax coating on the end grain to seal it up a little. I left the rest as it was as the oak I used was green. I just scrubbed it with a hard brush and some warm water. I used green oak as the bench is always going to be outside in the elements,so with no finish applied the oak will not require any maintenance and will turn a lovely silver over the years.

I am very happy with the way it has turned out and now safe in the knowing that my partners Gran will have a solid garden bench to sit on with friends while they enjoy the sunshine and the garden.

Mallet!

I have been looking for a while now at getting a nice wooden mallet for fine chisel work instead of using a heavy hammer. While on my search for a decent mallet it seemed that all I found was either way to over priced for what it was or very cheap and tacky which and would fall apart after a few projects.

So I decided to make my own! That way I could make it to what I wanted it to do and what I wanted it to look like. I had a rummage around it my stack of small oak off cuts and found a nice chunk of kiln dried 4x2 and a perfect piece for a handle.

I started by cutting the head to size and giving it a 5 degree angle on each end. I took the handle piece and a plane and started to taper it gradually testing the grip until I was happy with the thickness. Next came the measuring and marking out as the idea was to make a mortice right through following the exact sizes of the handle and ensure a perfectly tight fit. I marked the center of the head, top and bottom and sent a 4mm pilot drill through the make sure the hole was straight before sending a flat wood bit through to remove most of the waste.

Next job was to clamp down to head and begin the chisel work to remove the rest of the waste wood and to form the tapered mortice. Once I got to the inside edges of my marking lines I began testing the fit regularly to keep on top of the perfect fit I was after. It wasn't long before I was happy with the fit.

I grabbed a bottle of wood glue and a rubber mallet and placed to head in a vice and roughly worked out where the glue would need to be placed on the handle to sit inside the head. I applied the glue to both pieces and started to tap the handle down from the top until it wedged firmly inside the head piece. The fit was perfect and didn't really need and glue but it is in there anyway for added support.

Waited a few hours for the glue to set before taking some sandpaper to it and taking off all the edges and corners. A nice small coat of Danish oil to bring out the grain and a small amount of wax after it dried finished it off nicely.


 This is the finished mallet :

I am very happy with the result, the weight is just right and it looks a hell of a lot nicer than everything else I was looking at. After a few weeks of use it is still perfect. Still looks brand new and still solid.

It was an easy tool to make which I urge people to try making themselves instead of purchasing those on sale at the moment. Don't get me wrong, I'm sure many on sale are fine and perfect for the job its meant for just in my mind they just didn't work for my personal tastes. So why not try making one!? A basic tool kit and knowledge is all that's needed. Plus it will surely add to the satisfaction of using a tool you made yourself to complete a project!!

Starting it all up.

So... I have finally started to pull my finger out and push forward on my business. Around Christmas time (2010) I began thinking I wanted to make something of myself instead of just having a job that pays the bills. At 27 years old I must admit it has taken a lot longer to come to this point than it should have. I knew that I wanted to create something different using skills that I have developed over the years in the woodworking industry building timber buildings.

I got myself a pad of paper and a pencil and set about designing some furniture. I started with a coffee table that I needed in my living room as the one I had was to big for the space I had. I drew up a few designs and came up with one that me and my partner were happy with. I had the good fortune of having a vast array of tools and machines at my place of work which I could use and a large stack of green oak off cuts that were stacked up ready for being burnt. I swiftly saved all of the wood and set about machining the oak to the sizes I needed.

I knew straight away it was oak that I wanted to work with. I have been involved in many oak framed buildings in my place of work which I really enjoyed doing so oak in my mind was the timber I wanted to build with.

Ever since I started on this first coffee table project I have been amazed at how much I enjoyed doing it. I am not trained as a fine furniture maker but I do have a massive attention to detail that I am committed to uphold. I'm researching and learning through books, magazines and the internet in which I have learned a lot. A big chunk of the information I already knew being in the industry but I am learning and improving on my skills every time I make a new piece.

It has now been 5 months since I started making furniture which have all been coffee tables at the moment which I have been building on the part time basis as I still have my full time job. As of today I have 4 very unique designs that are strong, solid, interesting and different. Very different to anything out there at the moment and I have had a lot of positive feedback.

This weekend has been time for me to get myself a blog and a website domain to get my furniture on show.

This is where I am at the moment. I have many designs drafted up which I am excited about making a start on. I hope to get a handful of coffee tables, a few bed frames and a selection a garden furniture made in the coming weeks/ months all from solid oak.