some fancy cnc work

a while back, we worked with our neighbor, steve holman, on two large conference tables, one 9' x 26' and one 8' x 20'. we had to set them up in my garage as neither of our shops was large enough to hold them ... this fall he got a commissions to build two more 'smaller' tables, a 16 footer and a 14 footer. those both fit in his shop and were simpler in design, but we still helped by cutting the table and base pieces on our cnc.

one of the other parts of this project was a fantastic reception desk, designed by steve and paul molinelli, that was full of curves and different levels and was pretty complex as you can see from the photo above. click the pictures to enlarge them ...
so, how did we get from there to here ... it was easy for us. all we had to do was the full size templates, curved plates, and bending forms ... steve and his crew did the rest. i'm sure it could have been done without the cnc, but you would have needed some pretty big french curves to lay out the full size pieces. and then, the small adjustments ... it would have taken some time and some really intense bandsaw work ...
we started by scanning the scale drawing actual size and then drawing over it in our cad programfrom there, trevor imported that into the cnc router program and he added the elevation sections shown above ... next step was the 1/4 scale model you saw in the photo at the top. trevor constructed it by stacking layers of mdf of the proper thickness to correspond with the section drawings at each slice.from there it was a simple matter for him 'scale it up' to full size ... (increase; proportional) and then cut the full size patterns, counters to be veneered and their curved solid wood edges, and the plates from which steve and his crew created the curved walls and curved laminating forms.here are the walls, 'unskinned' ...
in some cases they were covered in wacky wood and veneer panels made with the curved forms, and in some cases, vertical 'siding' of 5/8th" thick solid lumber
next paul carved the 'car element' (this project went to an automotive company) and added the hood element from, i think, a 1937 ford or chevy ... cool ...
and then there was the other part to the project; the two conference tables. one 14' long, and one 16' long ...
this one is makore veneer and cherry. after i did the cad drawings, trevor programmed and cut the vertical elements of the base and the 'outriggers', the horizontal elements that receive the cross bars that support the top. he also cut the top sections to shape and the matching solid wood borders, as well as the holes for the power/data fixtures.
this is a section of the walnut and walnut burl table. ditto for this one except for a little adjustment to the thickness of the inlay panels. for whatever reason, the pockets trevor cut in the top sections were a little too shallow (there were two sets of burl panels made as the first one was 'too dark and burly', so, i suspect that was part of the problem. anyway, it was a quick, though somewhat nerve racking fix. after milling pockets in the spoil board he took a few thousandths off the backs of the panels so that the 1/40th inch veneer panels were just a shade below the surface of the 16th" veneered main table panels ... i'm glad i wasn't the one to level them up ...
but level them up they did ... and below, the solid wood edges are added to the top panels ...
the tables are probably finished by now, and maybe we'll see them before they go, or maybe we won't. anyway, we always enjoy working with steve and his crew. their projects are inevitably a rewarding challenge.

a commercial reception desk

along with the 14' fumed, fsc, quartered, figured eucalyptus table, we've been working on a painted reception desk for a client in boston. it's a crispy commercial project designed by the worldwirde architectural firm, gensler. the granite is from johnson granite and marble of proctor b=vermont. loyal readers may recall that they also did the granite for the large conference tables we made last year. click the photos to enlarge them ...
cad plan view and granite layout ..
no overhangs, everything flush and fitted ... though it looks easy, now that it's done, there were a number of interesting and exacting challenges to solve along the way ... timing was one, and we had to order the granite and the glass before we even started building the piece. the glass will actually not arrive until about a week after we deliver it this friday. fortunately, there is a commercial glazier working on site and he will install the glass when it arrives, saving us the trip.
the glass is mitered and 'back painted' and will cover the low protruding, overhanging counter face, the short return, and the far end, and is bordered by 1/4" satin stainless edge pieces. not having the glass on hand, we cut mitered 1/4" mdf panels on the cnc to the exact sizes of the glass we ordered and hopefully, our tape measures are the same. there is not much room for error and few places for adjustment now that everything else is finished.
we made a slick jig for sanding the stainless steel edges and sent them on edge through our wide belt sander. probably not a recommended application, but it was the only way we could come up with, and it worked perfectly ... the flat pieces were no problem and we sent them through with the exhaust off and used an old 80 grit belt. there were virtually no sparks or heat build up, and i would say it was a valid technique for surfacing them to create the 'industrial' look required.
the miters were cut to rough length and adjusted and fitted using a 45/45/90 jig on the edge sander.
we framed the piece with timber strand, a stable flat stud material becoming more popular in high end housing projects around here. it's not cheap, but it is flat, straight, square and stable. except for the weight, it's a pleasure to use.
we also created a flip down 'door' for the electricians, which i am sure they will approve of ...
and a sturdy 8/4 ash and steel frame to support the +/- 600 pounds of granite counters.
the blue line denotes the largest piece that had to fit in the freight elevator .. 44 x 42 x 80".
the granite was cut from one large slab so the grain matches over the entire counter surface.
lastly there is a little box of drawers that supports the frame end and ties everything together. below you can see the steps in the simple assembly. looks easy now that it's done.
the corner piece will be set first over the wiring feed and the L shaped 'glass' piece is attached from the inside of the desk.
here trevor is installing the screws to secure the two main pieces together.
the granite frame is next. it sits temporarily on two angle iron pieces, and then is securely bolted to the stud framing with 4" 'timberlock' hex head lags.
the drawer box is slid in to complete the base assembly and the removable panel on the inside back wall is installed last.
the first piece of granite is slid into the corner, and the rest are added to complete the puzzle.
and while we were at it, we put some cardboard on the top of the eucalyptus table frame and took a quick snapshot ... all in, all done .. onto the truck for boston tomorrow.
crazy wood that eucalyptus ...