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!

Finished coffee table.

I have completed my most recent coffee table project with amazing results. A simple design with stand out features make this a coffee table that stands out in any room it will be placed. The huge knot that takes over the whole of the top is a gorgeous feature that you just cant help but admire.

You can see in the sunlight that this coffee table is very unique. You can never get these colours and patterns in the same place like this again. The large knot really makes this coffee table. But looking round this piece you will see other amazing lines and colours throughout the whole table.

The rounded edges on the legs and angled feet give this table a simple but eye catching appearance. Hand cut mortice and tenon construction makes this a fully solid and sturdy coffee table. The gorgeous whole waney edged top is held down using screw and button method. This allows the top to naturally move without twisting the table out of square.

There are some very beautiful medullary rays (silver grain) running horizontally on the inside of the legs that just add to this tables large list of unique features.

I really enjoyed making this coffee table and I am over the moon with the end result!

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.

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!

Oak beam bed frame

Me and my partner have recently purchased a new matteress and were looking at bed frames but the cost of a nice, decent bed frame nearly made me fall over. I knew I could make myself one that would be bigger, better and constructed to a much higher standard all for cheaper than a half decent frame to buy in the shops. All it would take was the cost of the timber and my time.

I designed an extravagant frame using 150x150 oak building framing timbers and I managed to get timbers, air dried for 6 years at the sizes I needed kindly given to me. I also got some 150x75 Ash which I decided to use for the rails instead of oak. So I have not paid out anything for this bed frame.

Setting out on sanding all the edges down revealed some amazing character including cat paw knots and masses of medullary rays. Working out for all the joints was a task in itself due to the timbers being curved slightly as well as twisted.

I am cutting the mortices and the tenons by hand along with all the timber lengths. The only machinery used will be a belt sander and a drill.

I am at around the 40% complete stage at this moment in time.

This is my main project so updates will be regular and images will follow shortly.

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!

Etsy Shop now open!

My unique handmade solid oak furniture is now available to buy direct from Etsy.

My shop is http://ryondesign.etsy.com

Check back often to find new items for sale.

Social networks!

I best add my information of my presence on social networks.

Facebook - Ryon Design

Twitter - @RyonDesign

Like/Follow me to see items currently in production and all my plans and ideas. Get your name down before anyone else for something you like before it goes up for sale!

New Gallery Pictures

I have another coffee table in my gallery. This one is a definite one of a kind piece. Everything you see on the gallery page now is available to be made. Remember no two pieces will ever be the same and I want to keep my products as one of a kind pieces. Similar... but never the same.

As they are made to order anything and everything can be custom. Length, Width, Height, Finish, even the Design if need be.

Think of anything you want made. You know that you will never find what your thinking of in the shops. I could make those thoughts reality. That's what I want to do! I don't want to make bog standard furniture!



Lets create something amazing!

Frankenstein furniture.

As well as wanting to make gorgeous new oak furniture from scratch I have recently started thinking up ideas which will combine many pieces of furniture together to create something different. Not necessary beautiful furniture, again just going with a different feel.

I will soon be setting myself a small challenge to have a go at this idea. I am thinking everything I will use must be pre owned and only obtained at places like car boot sales, freecycle or homeless charities like Emmaus. A small amount of cash per project and a limited number of pieces to use.

So for example. I will have £20 to get 3 pieces of furniture from Sundays car boot sale. Then create something by combining them all together.

I am thinking this side of what I'm creating only using recycled materials. Nothing new at all. Apart from glue and maybe fixings!

Some very crazy things running through my head with this in mind at the moment! Lets get this started!

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!!

I am starting to design a few more pieces to build.

I have been drawing up a few designs lately for items such as a chest of drawers, bedside cabinets, and bed frames. I am considering making a whole set with the same design for a whole basic bedroom set.

The design I am considering is going to take a lot of time. Every face of every section will be detailed heavily to create a complex piece of furniture that will be amazing to just sit and look at.

This is going to take a long time!

A little light reading.

I have been researching and learning at the same time as perfecting my joints in my work. I have been flicking through a great book called Wood Work The complete step-by-step manual. This book shows everything you will ever need. It has very clear images and everything is worded so you instantly understand. From how to sharpen hand tools to building a huge welsh dresser step-by-step.

A great book in my opinion!!