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Showing posts with label custom kitchens vermont. Show all posts
Showing posts with label custom kitchens vermont. Show all posts

Friday, August 17, 2012

sheldon slate, granville, new york

sheldon slate, granville, new york


while working on the designs for the custom kitchen we started this week, our client and i went to visit a local slate fabricator, sheldon slate, in middle granville, new york. it's about 15 miles up the metawee valley through the corn and over the border ... who knew?
what a place !!! that's a 90" diamond saw blade spinning at about, oh, i don't know, 2000 rpm?, slicing through about a 3' x 4' block of slate, 3/4 of an inch at a time, cutting both ways .... click the photos to enlarge them ..
a view from the side ... we're sawing very unusual red slate today ... twice as hard, twice as much breakage, twice as much waste, twice as expensive ...
but oh my, maybe twice as beautiful ... these are pretty big pieces, like 66" x 57", and the rain made them just glow ...

you gotta love the scale of these tools. i think it was about 10' between the uprights on this bandsaw.  our tour guide, gary, told us sometimes the blocks are so heavy they can't pick them up off the huge dump trucks they come in on from the quarry and they just back the truck into the mill, cut em in half right on the truck, then drive it back out and unload ...
the view out the back door there looks over part of the quarry and south to haystack and home ...
and out the other door, the acres of inventory
including a little roof slate, like maybe 500 square or so ..
loved it, and i didn't have my camera for the first half of the tour where we visited the honing/planing/milling section ... more big tools ...
we were there to look at the available colors and give them a heads up that we would need some pretty big counters ... the one on the right will require a piece about 6' wide and 7' long with some angles, sink and faucet holes and a custom made 42 x 21 x 12" deep matching slate sink. the one on the left, about 50" x 100" ... no problem ... just bring your checkbook ... more on the kitchen soon ...
we're underway, site check today ....

Sunday, July 29, 2012

7 28 2012 ... action!

7 28 2012 ... action!

well, what's happening here this past week you ask? where to even start? it's a busy time and there is a lot going on. click the photos to enlarge them ...

our main project for the past two weeks has been the pool table above, in walnut and blistered maple, with some burl and mother of pearl accents. it's a standard 8 footer, and the drawing below is a modified version of a table we built about 10 years ago for a local client.
that one had tapered legs but this client requested straight onesthere are a lot of parts and steps and assembling and disassembling that go into making a pool table and the selection above shows most of them in the rough. the 3 piece slate, the 16 pieces for the legs, the rails, the panels, on and on ..
we started with a plywood leg mockup for size and colors and moved on, a step at a time to the photo at the top of the page ... even after 14 other tables, we still follow the steps outlined in a very excellent fine woodworking article by paul bowman from fine woodworking issue #75.we're on the home stretch. will will finish the mother of pearl inlays tomorrow and start on the blinds, and trevor will glue the inlays into the legs once the frame is disassembled. actually, trevor will do that after he returns from delivering the 10' claro walnut table above to stowe with jim tomorrow.classic design, with our shaker inspired blackened 1.5" thick steel legs ...
and terrific grain and figure in the top ... this slab is from the same log as the expresso finish table we recently shipped to chicago.
and will finished up banjo #11.
it was a surprise birthday present to sarah from her husband john and it was REALLY a surprise.
they are nusician friends of will's and john said they were going to 'stop by' to see will and tour the shop. at the end of the tour, will showed them the new banjo he had just finished. when she asked who it was for and told him how 'perfect' the inlays were, john told her it was for her and she said 'yeah, right'. perfect. she was surprised.
and next saturday, the 2nd annual 'vermont artists show' opens in town. last year it was a great show and this year i'm sure will be equal to it or even better. we've got a small claro coffee table
with a rainbow finish steel base that we will wrap up in time for the delivery later this week coming up.
and we've got a kitchen commission in the design stage. next up are the full size cardboard plan views to be checked on site before we begin. the wood arrived this week and we will start cutting it up as soon as the pool table goes to the finish room ... we've got about 6 weeks to finish it and install it with its friend the kitchen island we wrapped up back in may.
and will finished the reclaimed oak bench/settle that's been in the works for a couple weeks. looks great and it will be off to the upholsterer's shop to be measured for cushions shortly. and this past week, a first, the 'owner built table'. paul kelly, a teacher at our local high school, commissioned a table with wood that he had bought locally and then asked if 'he could help' with its construction. well, i knew he was a clever guy and a friend, and thought, why not ... it turned out to be a pleasure for everyone in the shop and we especially enjoyed having connor and ryan around to help with the heavy lifting. great kids, and it took me back to my early days in the shop with sam and will occasionally 'helping out'. paul dubbed it the 'father and son' table and even caught a shot of me and will doing the final inspection before it left for the finish room.
it's a classic 'bethlehem steel' design with two book matched planks that we swapped end for end to make a less tapered top. we put a small bevel on the planks before we glued them up and the sap wood made a pleasing design in the center.
and trevor figured out how to make a 5" thick slice of white oak 4" thick for an upcoming boston project that sam will make a metal base for ...
as soon as he adds the arms to these metal porch chairs for a client in peru.  not that peru, peru, vermont. i liked the design so much, i commissioned sam to make a one armed version for our own porch. the cushions will be finished this week ...
i was thinking of adding a wood arm over the steel, but i kind of like the negative space and the fact that it isn't connected to the back structure. maybe just a small wood arm with room for a beer holder .. we'll see ....
and we had some rain and the local (end of the driveway) chanterelle patch is producing again ... these wild mushrooms go great with most anything, from salmon, to eggs, to meat loaf ... can't beat 'em.
summer's great in vermont ... all for now ...

Saturday, February 19, 2011

It's A Wrap

It's A Wrap

the big island is in its new home ... after a month or so of awaiting finish sample approvals and then actually doing the finishing, delivery and assembly, we're done ... it was nip and tuck getting it out the front door, but we got it, and, it looks great on site, perfectly proportioned to it's new room, which is, actually, quite a bit larger and at present, emptier than our shop ... it was a challenging and engaging project on a lot of levels and i look forward to seeing it with the appliances, sink and granite as well as the rest of the furnishings for the room in place ... onward ...

click the photos to enlarge them ...
from the dining room side ...
the piece is lightly distressed at the early stages of the finishing and we sanded the broken edges a little more aggressively than usual as the finishing progressed, creating highlights on the corners and a 'softness' than is often found on well used antiques.
carry it in ... set it down ... perfectly level over the entire 16', both ways ... we jacked the shop floor up to all level before we started because, having worked with this builder for almost ever, we knew it would be this way ... with the design as it was, there was no place for shimming anyway ... all good ....
here trevor is installing the steel granite overhang support. it's 1 x 3 x 1/4" rectangular tubing stiffened with the box beam cross pieces visible in the photo below.
the finish schedule was a variation of our typical finish process using lockwood dyes, minwax fast dry polys, gel stains and wiping polys. see more finishing posts here ...
we made a couple different sample boards before we got what we wanted ... i can't remember the last time we used stained quartered white oak for a piece and i'm pretty sure we haven't ever done a distressed, stained version of it before ... i'm happy with the results. on the sample we gel stained before the seal coat which, in my opinion, requires a longer dry time before the top coats and is slightly harder to manipulate on the unsealed wood ... next time i would do as we regularly do and seal the second coat of stain in before applying the gel layer. it was a big finishing project and took a long time but as in cooking, what step/ingredient would you leave out? in my 30+ years of experience and research, there are no shortcuts to a deep rich finish, only many, many steps ... ask the experts ...

there are a few earlier related posts for this project at the links below ...
turning the columns
getting it all together, attaching the columns and cornice support structure
finish process and delivery photos