Walnut Bell Frame
Recently a customer called to talk to me about a woodworking project and asked if I have ever built a bell frame. I told him, “No, but I am pretty sure that no one else you are going to find around here has either.” That may not have instilled much confidence, but I got the job anyway (it may have also helped that he was a friend of a friend).
My customer gave the bell to his wife for their anniversary. It was made in 1908 and weighs about 450 lbs. The bell and the new headstock and wheel all came from Whitechapel bell foundry in England, makers of Big Ben and the Liberty Bell.
The frame is made of walnut, which is very durable outside, and is mounted on a slab of granite from New Hampshire. I was able to get all of the major parts from one log that was perfectly suited for the job. It was straight-grained on one end, which I used for the feet and top rails, and it was curved on the other end, which I used for the four legs. I loved using the sawmill to cut the thick lumber and chainsaw to do the rough work.
One of the most enjoyable parts of this job was being able to start with a log, and in a short time end up with a finished piece.
Factory Cart Bench
I have been through a lot of factory carts in the past couple of years, all of which have been repurposed into coffee tables. Things changed a bit when we built our first factory cart bench. It came about when a customer that wanted to have a bench made sent me some pinterest photos and one happened to have industrial cart wheels on it. That was a gimme for me because I happen to have in my possession about 50 carts that are already bench height.
We started by trimming the whole thing down from 28″ to 19″ in depth and cleaning all of the hardware. That was followed up by building the back and armrests out of wood we saved from other disassembled carts. After a little distressing around the new cuts and a light sanding overall, we stained all of the hard maple with a medium-dark brown stain before spraying a lacquer finish on the entire cart, including the hardware (I prefer the look of the hardware with a clear coat as opposed to black paint).
When the bench was almost finished, I told Chris (my wife) that I think we might need a factory cart bench in our house. She asked how much I charged for it and she then advised me that it would look much better in someone else’s home. I guess that is how it goes at the cobbler’s house too.
Hickory Wine Cellar & Home Theater
It started out as a simple wine closet, a small room to be built-in the corner of an unfinished basement. My customer has simple tastes and he really just wanted an improvement on his simplified (non) design that had left his wine collection in a closet under the stairs. In it he had a wine room cooler on the floor that was running with the exhaust pointed out the semi-shut door. I don’t think it really helped the quality of the air, but it could still qualify as a wine cellar, at least in very loose terms. No matter what you call it, it needed some sort of upgrade to take its rightful place in this custom Ladue home.
As I mentioned, he has simple tastes, but apparently his wife does not. On my second meeting with him, he pulled out a photo book with a lavish French theater that his wife had found and said that since we were going to build something downstairs and he had the extra room, he would like to add a theater to the mix. It was a giant jump from where we started, but I did not argue.
The theater room quickly took shape with our new directive, and the wine cellar followed, becoming equally involved and in a French country style, which called for the racks to have more of a furniture feel. The nine pieces, the arched entry door, and the two beams in the wine cellar where made from a batch of hickory logs that I recovered from a tree service a year earlier. It turns out that about twelve months is the perfect amount of time for hickory to get very wormy and nicely spalted.
Much of the racking in the wine cellar is traditional, with ladder racks holding the bulk of the collection, but each piece of furniture displays the wine in different ways, from individual bottles to entire cases. One of my favorite little details that I commonly use now in other wine cellars is adjustable shelving. I know it doesn’t sound earth shattering, but in a wine cellar the shelves can be used flat for case storage or offset with a tilt for displaying individual bottles. The shelves have a strip across the front which is flush on top and forms a lip on the bottom, which when flipped over keeps the bottles from sliding off and crashing to the floor. The tilted shelves are especially helpful for holding and displaying odd-shaped and larger bottles that don’t fit in the other racks.
Between the theater and the wine cellar is a spot for a poker table and a back bar made from rift sawn white oak cabinets and walnut countertops with art glass windows above. All of the woodwork around the windows is made from poplar that was stained dark brown and glazed with black for an antique appearance. The walnut countertop was built up to 1.5″ thick by laminating two layers of 3/4″ thick stock together. I have done this many times and it works great (click here to see how it’s done).
The theater itself involved a lot of trim details. The ceiling is broken into three sections with painted beams and large crown molding, while the walls feature a hand-crafted plaster finish and picture-frame moldings – all of which add to the French feel of the room.
From humble beginnings to this showcase of a job, things really changed. I would have never guessed that this is how it would turn out when we started.

The French Country style comes to life with big beams and wormy, spalted hickory throughout the wine cellar.
2014 Woodworking Projects
I am terrible at remembering to take photos of my projects. I usually tell myself that I will take the pictures next time since the job isn’t officially done yet, or the background doesn’t look great, or my shop looks like it houses six families of hobos, but when the job is unceremoniously complete, I set off for my next one without even a snapshot.
In an effort to prove that I actually do work every now and then, I have pulled together a quick photographic rundown of 2014. Some of them you may have already seen, some are new, and yes, some are still missing (just imagine all of the other swell things that I did that aren’t included).

This antique reproduction table was a little tricky to make. The smaller legs don’t leave much room for joinery.

My customer said to do whatever I wanted on this one, and I did. This spalted maple log wasn’t wide enough to make a one-piece top, so I made a three-piece top with the curved slabs. The top is shaped like a football with the ends squared off. A glass insert in the middle will finish off the top.

This round dining table is made of American elm (one of my favorites). While a bit cantankerous to work with, it yields beautiful results.

About 150 of these carts have made their way through my shop. Luckily, I didn’t have to refinish all of them like I did this one.

I used every durable wood I could think of for this play structure. Osage orange, cedar and white oak all teamed up for this preschoolers playground.

This mantel was milled from a piece of driftwood and the fresh cuts were stained to match the gray exterior.

Dark-stained cherry and iron (aged like a man) worked together to create a focal point for this new kitchen.

This contemporary TV wall is a slight departure from my normal projects since I didn’t mill any of the lumber. It is built from natural maple plywood and red oak plywood stained black.
Here’s to a new year of great projects and remembering to take more photos! Happy New Year!
Natural Playground for Preschoolers
The final touches have been put on the natural playground structure for Immanuel Lutheran preschoolers and they have already been putting it through its paces.
The deck, climbing wall and steps are made from white oak, the posts are eastern red cedar, and all of the twisty branches are osage orange. The three species of wood were chosen for their ability to weather the elements, while the white oak and osage orange have the added benefit of being exceptionally strong.
Thanks to the staff at Immanuel for being great hosts. They always greeted me with a smile and sometimes, even with cookies.
Using an Adze to Make a Hand-Hewn Finish on Wood
I was working in the shop last week doing some adze work on a couple of hollow beams and remembered back to my frustrating first days using an adze. I recalled a couple of tips that I wanted to share in this latest Quick Tip video:
For an extended description of the hollow beam making process and more adze fun click here to read How to Turn New Wood Into Antique Beams.
Easy Sign, Difficult Customer
At the end of May, my daughter and pickiest customer Mira, turned eight and planned to have a mermaid swimming party at Grandma’s house. Grandma has a swimming pool and we knew that she would be willing to heat it for an early-season swim, so it was an easy choice. The difficult part was finding mermaid themed items that met with Mira’s approval and weren’t for little girls (Ariel, A.K.A. The Little Mermaid, is not cool when you are eight).
While searching for party decorations, my wife, Chris, came across a little sign that she thought was cute and asked if I could make one for the party. It said, “Mermaid Lagoon” and it was pretty simple, and since it was right up my alley, being made of wood and all, I said “Yes”.
I dug out some cypress that had lots of knots and a good rustic look and started cutting. I wanted the sign to be bigger (who wouldn’t) than the one in the photo, so I cut the boards about two feet long to make the height. I trimmed the ends at random lengths, some at a slight angle, until I had enough to make the sign about three feet wide. It went quick, especially since I had no formal plan. If a board didn’t look right, I just trimmed it more or flipped it around or just grabbed another board. I love that kind of woodworking; no tape measure, no pencil, no worries.
After I nailed the boards together, I painted them with a wash of blue/green paint. I already had some bright blue paint in the shop and added green Transtint to get the color right. I thinned the paint down with water and brushed it on as quick as possible. While it was still wet, I wiped it off like it was a stain to show the wood below.
Once the paint was dry, I did the lettering, which I laid out and printed from the computer. I cut out the words with an X-acto knife and used a light coat of Super 77 spray adhesive to hold it in place while I painted it. A light mist of white spray paint did the trick, making the words legible but not too pronounced.
After the sign panel was assembled and painted, I needed to come up with a post. My first attempt was a weathered piece of oak 2″x4″. It had the right look and feel since it was old and gray, but I thought that Mira might not approve since it just looked like an old board, so I continued to search for a better way to display it.
A quick walk to the other end of the shop revealed a piece of driftwood that was perfect. It was the right size and height, and with just a little block added to the bottom, it sat up beautifully crooked. Plus, I wouldn’t have to pound it in the concrete-like ground since it would stand up on its own. That piece of white oak driftwood couldn’t have worked out better.
All that was left to do was screw the sign to the post, which took a grand total of 30 seconds. If it was going to be for long-term use I would have been more serious about it, but two 3″ deck screws worked just fine and quickly put this job to bed.

The perfect piece of white oak driftwood and cypress lumber teamed up to make this sign for my daughter Mira’s swimming party.
I was pleased as punch. I showed it to everyone within shouting distance of the shop and couldn’t wait to bring it home and show the girls. They were pleasantly surprised at how it turned out and I was pleasantly surprised that Mira quickly approved it (I was still a bit worried that my unauthorized driftwood addition might have been a bit aggressive in her mind (even though it was perfect)). We capped the whole thing off with hot glue, a few seashells and then perfect weather for a “Mermaid Lagoon” swimming party.
The sign now resides in my shop, where it generates many inquiries, but as of today, no more official orders for driftwood mermaid signs.
How to Make Realistic Worm Holes in Wood
If you want to make something look older, just add some worm holes. Sounds simple enough, but there is a major difference between just poking holes in the wood and making the holes look authentic. Now that the all natural, rustic wood look is in style, even new, or at least not very old wood often benefits from more character, and I am here to show you how to really do it.
First off, let me assure you that I have a lot of experience in this field. I often build pieces that need to be “wormed up” in some regard, either to make new wood look old or to make old wood look even older. Especially on projects like beams and mantels, worm holes help add a lot of age to a piece.
Much of the wood that I use already has worm holes in it because I let the logs sit awhile outside before I mill them into lumber (sometimes even on purpose), so I have a head start, but there will still often be spots without bug holes where the wood needs a little extra love, like in the following video:
To get things started, it helps to first look at truly worm-eaten wood. There are consistencies even in what looks to be very inconsistent patterns. Here are a few principles that hold up in most wormy wood:
1.) Hole sizes vary: Even similar-sized holes are not the same. Your method for creating holes should easily produce random results.
2.) Worms tend to focus their efforts: Holes will usually have an area of focus, with more holes in the center of an infected area fading out to fewer holes.
3.) Not all holes are perpendicular to the surface: While most holes are just that – holes, many are oblong and some are more like trails.
4.) The bugs that make the worm holes often enter around defects in the wood: Soft or punky wood, spalted wood, cracks, and sapwood are all areas that will focus worm activity. Good, strong, solid heartwood is the last area to be bug infested.
5.) Small holes outnumber the big ones: Older wood that has been attacked by multiple insects will have lots of tiny holes (1/16′ diameter), some medium-sized holes (1/8″ diameter), and just a few big holes (up to 1/4″ diameter).
Here are some photos of authentic worm holes. If you can copy any these patterns you will be off to a good start.

This section of pine shows a nice array of hole sizes from large to small. Notice how the long holes follow the grain.

This section of hickory has holes that make short lines. They are also very dark and almost seem stained.

The holes in this white oak are larger and have stains around them where the wood has started to decay.
Here are some of my tricks for achieving realistic results:
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A scratch awl, normally used for marking projects, is the perfect tool for making small to medium-sized holes, after being sharpened to a long, tapered point.
Small holes. You’ll be tempted to use a drill bit for the smallest holes, but it isn’t the best choice. Tiny drill bits break easy and the size is too consistent. Plus, they pull out wood fibers that make the edge of the holes fuzzy. Instead use a nail or a scratch awl sharpened to a long fine point. A scratch awl is the best choice because it can be used without a hammer and produces speedy results. The long point will make different sized holes depending on how deep it is pushed into the wood. Push the scratch awl in the wood at different angles and different depths.
- Large holes. Use a twist drill bit for the larger holes. Be sure to drill deep enough that you can’t see the bottom of the holes and to vary the drill angle. Put the bigger holes in the softer wood. Sapwood, punky wood and areas around defects are a good place to start. Mix up the sizes in the 1/8-3/16″ range for a more natural look.
- Oblong holes. Some of the larger holes tend look like small jelly beans. Drill in fairly deep and then use the side of the drill bit to cut a short trail. The result is similar to two holes drilled right next to each other.
- Trails. Trails are often left just under the bark in bug infested logs and sometimes inside the log. Use a twist drill bit about 1/8-3/16″ in diameter and drag the bit in different lengths of crooked lines. Be sure to make some of the areas have more depth. Think of the trail as a river with shallow areas and deeper pools. Trails can have one, both or none of the ends finishing in a hole. Mix it up and have a few ends disappear into holes made with the same drill bit.
One of the most important things to remember when making worm holes or using any other techniques to age wood is to really go for it. You won’t destroy a piece of furniture by adding a few more holes or dents, and you can only miss by doing too little to the surface.
I often see furniture, especially mass-produced furniture, that will have some sort of distressing that looks like it was just phoned in. Usually, someone quickly takes a chain to the surface or pokes a few holes and calls it a day. Don’t do that. Pay attention to Mother Nature’s work and try to duplicate it. And, most importantly, have fun doing it.






















