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.
New York has a lot going on and a lot going for it – space is not one of those things. If you are not a people person, it probably isn’t the city for you. If you like to have room to work and a place to put your stuff, it definitely isn’t for you. Luckily, I am used to working in a tight space with a lot going on, and I don’t mind it. It doesn’t speed anything up, but as long as everyone isn’t too grumpy, working in tight quarters can be kinda fun and exhilarating. It only becomes less fun when it is time to get your stuff done and there is no way to actually get to it.
Our first installation trip in New York had both the joy of working closely with all of the other trades and the exasperation of having those same people in your way most of the time. I often feel like our shop is too small, but after going to New York and having 15 guys, a truckload of cabinets, a bunch of fridges and everyone’s tools in 1,200 sf. of showroom, I feel like I should shut up about it.
Click on the video below to see how much stuff we were able to put in a 5 lb. bucket.
Well, we got our cabinets to New York, off the truck and up to the 6th floor job site, but not without some excitement. I didn’t get it on video, mostly because it’s not easy to video while everyone is yelling at you, but I can tell you it would have made for some great TV. Will he get the truck unloaded on time? Will the other contractors let him live? Will the honking ever stop? All of these questions and more will be answered on the next episode of “This May Not Have Been a Good Idea”.
It started out great. The driver was there by 6 a.m. He pulled a magnificent u-turn in the corner intersection and got into the loading dock rather expeditiously, and everyone was joyous.
The marching orders from our general contractor were to get in early, claim your spot, unload the truck and ignore everyone else. That’s not really how it normally works for me, but hey, I’m in New York. You do what you got to do, and we did it. The first 30 minutes went great. Everyone we saw was still riding the adrenaline high of getting the truck in the loading dock. Then the mood started to change.
Other contractors in the building began showing up, early mind you, and couldn’t get in because we were in the way. Pedestrians started heading for work, also early, and couldn’t get by. Drivers trying to beat the rush could only use one lane. I know it’s hard to picture here in suburbia where we are used to having space.
We unloaded the truck as fast as we could, but it wasn’t fast enough. The yelling picked up and so did the honking. It seemed like everyone was on the phone talking to somebody else about how they were trying to speed up the process and get us out of there. Finally, the employees in charge of the loading dock said we were out of time and made our driver pull out and park in the street.
We focused on the truck. We got him unloaded and out of the way and at least stopped the honking. At that point I thought we were on easy street. The truck was gone and more than half of the stuff was up to the job site. All we had to do was get the rest of it up the freight elevator, and we had all day to do it. Wrong again. Turns out freight can’t be delivered after 8 a.m., so as not to disrupt the other businesses in the building. Fine concept, I just didn’t know about it. I have never worked in a building where the freight elevator can only carry freight before 8 a.m.
Right at 8 a.m. one of the building managers, popped out of the freight elevator, violently waved her arms as though she was calling a runner safe at second and yelled, “No more, no more!” She disappeared back in the elevator and we stopped moving. I didn’t know how to handle this one.
We stood there in the basement for awhile, knowing we had to do something. The freight elevator is big and we decided that if we got one more shot at it we could fit everything else. So, we went New York style, loaded up the elevator, made sure we got it in one load and headed to the 6th floor. We did not see the building manager and had everything officially off of the elevator and in the job site before 8:20 a.m., just a little past curfew.
Then our general contractor turned his phone back on.
Apparently, you just need to get used to people yelling at you when you work in NY.
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 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.
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.
It’s official. I’m going to end up with three installments about quartersawing. In an effort to not bore everyone to death in this video, I had to keep out all the important details, like why are we even bothering to do all of this extra work? There are a couple short answers (it’s pretty, it’s more stable) but since I like to give long answers, I’m going to need more time.
My focus for the last video was to show how I deal with oversized logs and this week I show how to actually quartersaw. I think it will help a lot for everyone to see, in a video, how riftsawn and quartersawn lumber are produced from the quartersawing process and see how I tackle the task.
Quartersawing a log takes much more time because each log essentially produces four individual logs (quarters) and each one needs to be processed separately. Throughout the process, lots of decisions need to be made to produce the most and best lumber.
Click on the video link below to see how the quartersawn lumber is cut and to see some really pretty boards.
I spend a lot of time talking about quartersawn lumber with customers and have always wanted to get my thoughts about it into one place. Turns out, it is probably going to be in at least two places when I get done covering it. There is just too much to know and the more I try to explain it, the deeper in the weeds I get, and staying out of the weeds is not my forte.
Since I have spent over twenty years discussing it with customers, studying it on my own and generally just worrying about if I am producing the best quarter sawn lumber as efficiently as possible, I have come up with a lot of talking points. Luckily, for you, I am not going to get too deep into it until the second installment, when I finish producing the quarter sawn lumber.
In this first video, I was most excited to show how I get a log which won’t fit on the sawmill prepared for quartersawing and to get a chance to use my chainsaw (which I do whenever I can). Click the link below to see how I get the large logs ready to be milled.
I just finished installing a barn door to cap off a bar area of a basement remodel. During its construction everyone visiting the shop talked about how pretty it was, and I agree. It’s weird because I didn’t imagine I would like it so much or get so wrapped up in terms like “pretty”, especially since I prefer to use the word “cute”.
Originally, we thought we might add some color to the individual boards, like maybe some washes of blue to go with the cabinets, but it turned out to be unnecessary. We wrangled up some wood in the shop from several different barns, and all of them stood on their own with no paint necessary. They were different enough that Tom, who built the door, even named them to keep them separated. The most textured gray pieces, which were sycamore, he called “dragon skin” and the smoother brown ones he named “Douggie Fir”. I think getting to know the wood really helped Tom pass the time at the chop saw.
The door is extra wide and turned out to be quite heavy, with two layers of hardwoods and a core of 1/2″ thick MDF, which required the wall hardware to be custom made and beefed up a bit. I got to visit one of my favorite places, Shapiro Metal Supply, to get the material and browse for a bit. The video below was shot just days before their recent fire.
While I did need extra muscle to get the door in the house (luckily they had a walkout basement), I was able to hang the door on my own. Click on the video below to see how it came together and see just how “pretty” it is.
I love visiting Mueller Brothers Timber in Old Monroe. It just feels right to me. I like the the guys that run the place and I like that it feels like I’m out in the country, even though I’m less than thirty minutes away from the shop. I visit there somewhat regularly just to see what is going on, look at logs and to purchase lumber. They run a big operation that I have written about before (click here to read more), but this time I decided to shoot a little video while I was there.
My main reason for visiting was to purchase some hard maple lumber for an upcoming project, since I don’t get hard maple logs, and therefore, hard maple lumber very often. While I was waiting for my lumber to be pulled, I took a look around the log yard to see if anything caught my eye (I don’t purchase logs very often – but I can be persuaded). I’m always amazed by the amount of logs that they have and this time they had even more than normal. I know I love to look around their sawmill and I thought you might too. Check out the video below to go on a quick tour with me.
Some quick notes:
The lumber bundles I am looking at are dry and available for sale, but they only sell by the bundle (usually in the 300+ bf. range). They move a lot of product and don’t sell in smaller retail amounts.
I mention cutting maple logs in the winter, which is desirable because the white (sap) wood of maple logs discolors and stains quickly and easily in warm weather. It is better to cut white woods in cooler weather because they decay or discolor more slowly.
I passed over the double-trunk white oak because I have a lot of white oak slabs and white oak is difficult to dry, especially when cut extra thick. Water doesn’t move readily in or out of white oak which makes the drying very slow and any attempt to speed the drying usually ends with the lumber splitting. Thick white oak can be dried effectively, just not quickly.