Anatomy of a Woodworking Project

Anatomy of a Woodworking Project

Have you ever thought about the process from start to finish of a woodworking project. There is alog ore involved in the process than you think. Most of us skip through each process not really thinking about how each step affect the overal project.

1. Fill a Need

I believe that in all things we do, we want to fill a need. Otherwise, why do them. The need may be basic or secondary. We also my not understand which need is which. The need may be materialistic or it may be emotional. You are someone you know needs a table, so you build one. But, is that really the basic need? I doubt it. I believe the basic need is more primal than that. Just as we need food, clothing, and shelter, we need an avenue for self expression and a sense of accomplishment. Otherwise, we would have bought the table. It certainly would have been cheaper.

2. Getting an idea

Where do you get the idea for your next project? Clues are all around us. Sometimes, ideas come from the most unlikely places. One word in a discussion can trigger an idea. For some, it may be a specific problem they are trying to solve. Others may be lucky and have the eye of an artist and have the ability to visualize an object. I will admit, I am not an original thinker. My ideas usually bome from a request from a customer or the desire to change something I have seen to make it my own.

3. From mind to paper

The next challenge is to move the great idea from your mind to paper. My first step is usually a sketch. then, there is a discussion wi the customer. All projects have a customer. It may be you, a lovedon, a neighbor, or if you are really lucky, a bonefide cash carrying customer whi is willing to pay you for your hard work. When there is an agreement on the sketch, my next step is a full size drawing. If at all possible, do not skip this step. There was a time when i felt that 1/4 or 1/2 scale would suffice. But, after completing some full scale drawings, I found it much more comforting to know that I had the exact measurement to work with.

4.Selection and preparation of materials.

This is an area where I believe much time and thought needs to be utilized to get it right. The last thing you want, is to complete a project and then realize that the wrong materials were selected. Aesthetics, project location/use, material strength, the mix of materials, and grain direction are just a few of the things that need to be considered. This is also another area where the customer must be consulted. For traditional furniture, there are many publications that can assist in you decision making. For an original project, the world is your palette.

For the first part of material preparation I use computer software. I use a product called 'Cutlist Plus'. There is a version of this software that cost less than $100.00 and you will recoup this cost in short order. Entering your inventory of materials, along with part sizes and how many of each part required, the software will create a cutlist that will make maximum use of materials.

The next step is to bring your material into the shop and allow it to acclimate to the shop for a couple weeks. When you start cutting material, cut each part at least 1/4 inch larger all around and a few inches longer.There are many stresses in wood and when cut, these stresses are relieved. You may or may not be able to see this right away. Let the material sit overnight. You will be surprised at how much movment there will be.I would also suggest that you cut some extra material to the same dimensions as your parts. There is always the possibility of an error somewhere in the project. Having dimensioned lumber available will reduce the stress level. DO NOT get rid of extra material until the project is complete.

5. Preparation of equipment

This is one of the most important, but often neglected parts of a project. If your equipment is not maintained and calibrated properly, you will encounter many moments of great frustration. Are your cutting tools sharp? Dull cutting tools cause many of the blood letting accidents in the shop. Inattention to the task at hand has caused many accidents. Before starting a new project, take the time to ensure that your saws are sharp and calibrated properly, so you can get that 90degree or 45degree cut exact. Make sure the cross cut sleds are exact. On mine, the thickness of a piece of painter's tape makes the difference between failure and success.

6. Execution

This is the fun part. It is also the part where the most mistakes can be made, in material and in you. Never ever work when you are tired, or are unable to give full attention to the task at hand. Missing body parts are not worth it.

As the old saying goes, measure twice and cut once. It is extremely easy to turn a 5 /14" cut into a 4 3/4" cut. Believe me, I have done it. Take time with your tools, Do not push them beyond their capability. Wixey corporation, makes an angle gauge that will great enhance you accuracy when setting up a saw for a particular angle. Try to use the same ruler throughout the project. Minute differences, between rulers can cause problems when trying to assemble a project.

Do not get in a hurry to start gluing things together. Always to a dry fit to make sure things line up properly. Make sure your joints are not too tight. glue will make a tenon expand so is is almost impossible to insert it into a mortise. Making mortise and tenon joints properly, takes time and patience. I usually cut my tenons thick and use a rabbet plane to get them to the proper thickness.

Make sure you have plenty clamps, but use them judiciously. Improper use of clamps can rack a project out of square. When it is time for the glue-up, take some time to mask areas that may get unwanted glue on them. Try to use only the amount of glue required. Make every atempt to limit squeeze-out of excess glue. Finding dried glue that will not take a stain does not make for a happy day in the shop. Remove the excess glue and the tape when the glue reaches a stiff but not yet hard consistency.

7. Preparation for staining and finishing

This is an area that most woodworkers hate to do. But, it is just as important as the construction phase of the project. This is what everyone will see. Using whatever methods you like, all tool and swirl marks need to be removed. On some items, I will use a scraper. On others, I will use sandpaper. If using sandpaper, 220grit is as fine as I normally go during this process.

8. Staining and finishing

There are many different forms of stand and finishes. All have their pros and cons. Before applying a stain to your project, take time to test different products and processed on scrap wood of the same type as the project. Perform the complete finish process on each piece of scrap so you will know what the project will look like when complete. After determining which product and process looks the best, do not skip or change any part of the process when finishing the project. Small differences in the finishing process can make a drastic change in how the completed project will look.

9. Post finish

Now it is time to really make your project shine. Do not get in a hurry to start this process. Wait until the finish is completely cured. Some products will cure overnight. Others may take weeks. You, most likely will need to buff or polish the finish to get that silky smooth look and feel everyone seems to want. Most people will rub a finish to get an impression of how well the finish was completed. There are many oils, polishes, and powders that will create the finish you desire. Please read as many of the finishing books as possible to get an understanding of the finishing process.

Now go and show off you hard work to anyone who will look. But, please do not point out every little blemish. Most people will not notice.Enjoy the moment.

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