Installing Live-Edge Floating Shelves in a Corner (and Wall to Wall)
Floating is pretty much the only way we install shelves anymore. We could install them other ways (you know, with brackets), but nobody wants brackets anymore. So, you might ask yourself, “If the only installation being requested these days is floating and the kids at WunderWoods install a lot of shelves, why was was it so hard for Scott to figure out how to put live-edge shelves in a corner?” Seems like he might have run into that before. The crazy answer is, no, I have not run into it before and no one has ever asked.
If you don’t give it a lot of thought, it doesn’t seem too much more difficult than a regular floating shelf installation. However, I was starting to think it was impossible (especially wall to wall) until I dreamed up a way to do it months after the initial request. While I was working on it and letting this part drag on, I remembered thinking, “I wonder how long it will be before brackets come back in style, so I can put up these corner shelves?”
My first, and only other plausible solution, was to install the rods and drill the holes at a 45 degree angle from the corner and slide the entire assembly (both shelves together) into the corner. This would technically work, if the corner is open, but it wouldn’t work if the corner was closed in on the ends and it sounded ridiculously hard to drill and install. It pretty much would never work. That was it. That was all I had for a long time.
I kept thinking about regular shelves and how nice it would be if I could just drop it on some shelf pins, or how nice it would be if they were just square-edged shelves and I could slide them in without fussing with that inside corner where the live edges crash at some random angle. Then, finally, I put the two ideas together. Slide the second shelf in at an angle on a post and drop the other side down into a funky joint on the other shelf. It is a tough one to explain without me being able to use my hands, so I put an animation in the video for you to see how it works.
Overall, the installation is the same as we do for live-edge mantels (click to see how to install a live-edge mantel) and other live-edge shelves. We do sometimes use Sheppard brackets, but they wouldn’t work in this case either. The main difference for this installation was the inside corner, which was cut on the CNC router. It’s a fun little joint which we cut quite often but with the addition of a little ledge. Check out the following video to see how it works. It’s a lot easier than me trying to explain it.
We’re all done in New York
We finally did it! After several months of work and me saying, “This is the last trip” a few too many times, we have finished up our install of the True Residential Refrigeration showroom in Manhattan. When this started I hadn’t been to New York (when I was old enough to remember), and now I can get from St. Louis to the job site in just a few hours and not even look up from my phone. It’s crazy to think what a difference a few months can make!
While we where finishing up we shot our last video for the job, which is below. Watch until the end (or just fast forward) to see the final product. Now, it’s time for some good ol’ toasted ravioli.
Festool Domino Connectors Pull It Together
About two years ago we started using Festool Domino connectors in the shop because we were working on a trade show display which needed to pack flat for shipping. The metal connectors are made specifically for this occasion, and if you have ever put together a piece of breakdown furniture (think Ikea), you have probably used something similar.
The connectors work great, fit into a normal Domino slot and are easy to use, but since they do require an access hole to tighten the lockscrew, they can’t be used everywhere. And, just like a Kreg screw connection, there will be never-ending discussions about whether or not this is “real woodworking”. Regardless of how real they are, the connectors have found a place in our shop and recently we found another great use for them.
Jeff, our building and finishing extraordinaire (he can do it all), was working on a desk which came together at some funky angles and decided to try the Domino connectors for alignment and clamping, and it worked great. The corner joint, which he glued together, lined up perfectly and pulled together tightly. Previously, we used other variations of under counter hardware an/or wacky clamping setups to pull the joint together and they always seemed a bit amateurish, like we were just making it up as we went, and often we were. But, not now.
Now, we are using the Festool Domino connectors not only for pieces which need to breakdown, but also for connecting and clamping those hard-to-clamp joints. And, just recently, we built a big walnut bar which required both, in the same piece. We had several joints which needed to clamp together permanently, and since the bar was very big and U-shaped, it needed to come apart in the corner to be assembled on site. The Domino connectors worked perfectly in this case, and I am sure you will be seeing more of them in the future.
Click on the video below to see how the project came together and how the connectors made it all possible.
Not All Trees Are Created Equal
Recently, I got a call about a walnut tree which fell in a storm. The homeowner knew it was a walnut and gave me a call to see about doing something with it, hoping to sell it. I get these calls regularly, especially for walnuts, and I always follow up so I don’t miss the good ones.
Even though most of the calls are about walnuts, most of the walnuts aren’t much to talk about. I’ll ask questions about the diameter, where they and their tree live and why they took it down, and though these questions will get answered, the overwhelming theme is, “It’s a walnut”.
Well, just because it is a walnut doesn’t mean it is a good walnut. I have received plenty of calls where I never bothered to pick up the tree because I could tell that the tree wasn’t great and the owner was way too attached, and often, they want me to take down the tree.
I only pay for a few trees a year. I don’t really mill that many logs overall, and they are readily available just for the asking, so there isn’t much incentive for me to spend money on them (really, almost all of the logs I get are free). But, this one was different. It met all of my criteria for a tree to both spend the time and effort to retrieve it and to also pay the homeowner.
So, what makes a tree stand out from the rest and why is this one worth paying for?
First off, yes, it is walnut. You now have my attention. Species does matter and walnut is at the top of the food chain for our local trees here in the St. Louis area. For example, walnut currently sells for $12 bf. while other hardwoods like hard maple, white oak and cherry are in the $4-$7 bf. range. But that doesn’t make it a good tree, that just makes it worth a good close look.
Diameter is currently the biggest driver for me deciding how bad I need a log. The bigger the diameter, the more options there are and the more wood overall. I draw the line at 24″ in diameter on the skinny end of the log, inside the bark. Any smaller than that is a tree which I can easily find and usually procure without spending money. Though smaller logs do still have value, they don’t have enough value and I will not pay for a log under this size. The 24″ size gives me the option to make bookmatched dining room tables (usually 42″ wide) out of only two pieces. If we end up going to a three-piece table top, I only really need an 18″ diameter log and those are widely available at no cost. This walnut was over 24″ in diameter at 30′ from the ground, so it was the perfect size for what we do. Length isn’t usually a problem, but I do sometimes get calls about big diameter trees with very short trunks which branch off close to the ground. The longer the main trunk the better and this tree had a super long trunk.
Location is the second thing I ask about when discussing a tree because it affects so many aspects of the growth and my ability to process it. First off, the location affects the way the tree grows overall. A tree which grew in the open is usually short, wide and branchy. This one obviously, started its life with trees around it and reached up, producing a nice long trunk. I am cutting this tree into slabs, but it would also produce very nice, straight-grained, knot-free lumber.
Location also affects what is in the tree, specifically metal like nails, screws, hooks, chains and wire. Trees which grew in a bad neighborhood, in a small yard usually have a tough life and are full of problem-causing metal. This walnut spent its life in a nice, big front yard in a happy neighborhood on a street which I know has produced a lot of nice trees and shows no signs of metal.
Location also affects how easy it is to access. I get a lot of calls about trees at the bottom of a hill in a back yard with a little gate and no way to get to the log. This tree was in the level front yard right next to the driveway with nothing around it. Access couldn’t be easier.
Overall health of the tree and quality of the logs is the last thing I look at. In this tree I looked for scarring from lightning strikes, busted branches, possible hollow spots and rot. The roots showed a little bit of decay, which could have led to some hollowness in the bottom of the tree, but it was minimal and ended up not affecting the logs. There were some busted branches from the fall, but all of the main pieces showed no signs of breakage. It was entirely solid and sound. On walnuts, the speed of growth also affects how wide the sapwood (white outer layer of wood) is on the log. If it grows very slow, the sapwood may only be 1/4″ wide, while on super-fast-growing trees in a wet, wide open yard might have sapwood which is over 3″ wide. I’m looking for a good balance for live edge tabletops with the sapwood about 1″ to 1-1/2″ wide, and again, this tree was perfect.
Everything about this tree was as I would have specified and the fact that it was already down and most of the top cleaned up made my assessment easy. It was nice to be able to get a look at the cut branches at the top and the busted roots at the bottom to get an idea of the quality of the inside. I could have only had a better look at the inside of the log if it was cut to length, but I told the homeowner that I wanted to decide where to cut it and do that myself. Besides getting my chainsaw stuck and my crane giving up at the end, this experience and this tree was as good as it gets in my business.
Back to the River
We are still finishing up our move from St. Charles to O’Fallon and trying to get as many jobs completed during the move as possible. It has turned out to be more roadblocky than the optimist in me is willing to admit, but we have been able to deliver a couple of things which were wrapped up before the shop was completely disassembled.
Our latest delivery was to Golden Eagle, Illinois, just across the Golden Eagle ferry from St. Charles. It is mostly farmland on rolling hills overlooking the Mississippi River and into St. Charles. The view is great and the feel is right for me. I even entertained putting the new shop and/or sawmill in that area to make a destination operation, but ultimately decided it was just too difficult to get to on a regular basis, and at $18 per round trip ferry it would be quite unaffordable.
Even so, I still think it is a pretty cool area and thought everyone might like the view from the other side of the river. Click on the video below to see this live edge walnut table delivery.
We’re Moving: It’s Officially Official
After 10 years in St. Charles, MO we are moving a bit west to 821 Midpoint in O’fallon, MO. We started moving in earnest last week, and this past weekend I officially pulled the plug on the tools in the old shop. There is no turning back now! The new building is a 12 minute drive west of the old location on Highway 70. It is a nice stand-alone building which can easily be found by just Googling the address. No need to aimlessly wander around a giant building trying to find the wood shop buried in the back corner. We don’t have a sign yet at the new location (of course), but you won’t need it.
This Saturday will start our conversion to the new shop. By then, all of the wood and most of the slabs will be at the new location. So, if you are planning to visit on Saturday morning (open 8-12), please report to the new shop. From then on, 821 Midpoint will be our official location.
To kick it off, I put together an announcement video so you can see the outside of the shop (that was the day I got the keys) and our first moving video. Click on the video below to check out the progress.
Installing a Spalted Sycamore Fireplace Mantel
Years ago, I posted a video of me installing a mantel which was shot by my daughter Mira, who was nine years old at the time. The video did a fine job of covering how to install a mantel and has gotten a lot of views through the years, but it has also been heckled quite a bit. Most of the criticisms (which I have since deleted) revolved around the lack of a tripod and the poor videographer.
I was attempting to get my daughter involved in the business even though she had no interest in woodworking, so I thought shooting video with the big camera might do the trick. Though the video is indeed shaky, we had a fun time doing it and it has served its purpose, allowing customers to have a reference to watch so they can see for themselves how to install a mantel.
Ever since the negative comments started rolling in, I have wanted to reshoot a mantel install video and now I have finally done it. This time, I used a tripod and Mira wasn’t involved, so if anyone has a problem with the video, they probably just have a problem with me.
This install video is specific to the piece of spalted sycamore I used and the fireplace it went on, but all of the techniques are the same ones I use on most mantel installs. If you are installing a mantel and have any specific questions on how to do it, feel free to ask. I will respond and add it to my next mantel video. In the meantime, check out the video below to see how I do it and the small changes I’ve made through the years.
Installing New French Doors
Installing doors isn’t the quickest and easiest thing to do. They need to fit well, with even gaps all around and they need to shut securely, but easily. It is a demanding task, which I decided to make even more so by adding a second door to the mix.
While challenging, you’ll get no complaints from me. I like this little finicky stuff almost as much as I like sanding. And, while that sounds like sarcasm, it is true. I really do like both. I find it rather relaxing to just chill out and get into the work. When I was working on these doors and shooting the video for it, I even thought about making a “slow” woodworking video, with the beautiful weather and the birds chirping and me just chiseling away. Maybe that will be for another video, when everyone is clamoring for me to slow down the action a bit and make the videos much longer (I expect that to happen on the 12th).
In the meantime, click on the link below to see my zen video on installing a set of mahogany french doors at regular speed.
Milling Curly Q Logs
I just milled a short hollow maple log for a customer which ended up having a fun curly Q shape. The log clearly had a wound along the side, running up the length of the log and it was never able to heal over. In the log’s attempt to close the wound, it added extra growth which made the fun shape.
While I was milling the maple log, it brought to mind a sycamore logs which I milled a couple of years ago. They produced some slices with the same curly Q shape, but they were much larger. I clearly remember being quite sad when I cut into the giant logs and discovered they were hollow. Just when I was about to make them firewood, I got a clear view of the curly Q shape and decided to save them.
There really aren’t many practical uses for these cuts, but they attract viewers like crazy in the shop and as far as I can tell have all ended up as pieces of artwork. Check out the video below to see the final product.
What’s Going on at WunderWoods
Everyone always asks what I do. Here's the answer. Click on the photo above for a short video tour and see all of the steps it takes to go from a tree to finished furniture.