Or, The Policeman’s Boot Bench… part 14
I spent today cleaning up the exterior of the Policeman’s Boot Bench. It is always a big step to start cleaning up a project ready to apply finish, not to mention a critical stage of the work – applying a finish will highlight any imperfections or mistakes, so taking your time to getting everything looking pretty “in the white” is time spent wisely. To get in the right mindset, when I came into the workshop I headed straight to my sharpening station and sharpened the planes and cabinet scrapers I expected to use. Even if I had sharpened them last time I used them, they went back to the sharpening table for a fresh hone. Not only did this ensure that everything was as sharp as I could get it (I don’t want any tearout when finnessing the exterior faces of the casework) but most importantly I found that it helped get me in the right sort of mindset for the work ahead.
I find that for final surfacing and clean-up work it pays to have a plan of attack – the last thing you want to do is brush shellac onto a surface only to realise that you’ve not cleaned up it up fully. This is all the more so for the boot bench, where the open fronted shelves means that there are a lot of different edges and corners to pay attention to. I decided to ignore the front of the carcase for this session, and to focus on the faces of the wide boards, starting at one end before moving onto the top, and finally finishing at the other end. This meant that I could gently roll the boot bench onto one end, and then finish work with it standing on the opposite end. Fortunately, the boot bench has enough weight that when standing on a pile of blankets it does not move across the floor while being planed.
Because I had left the pins of my dovetails slightly proud, it was important to flush these up without chipping out any end grain, before working the rest of surface of the end pieces. I used the little Lie-Nielsen No.102 block plane for this, which worked in a very controlled manner to slice away the proud end grain prior to smoothing the rest of the board with the No.3 smoothing plane. Although I normally use a 60 1/2 block plane, I really like the 102 for delicate work, as it is perfectly sized and weighted to fit in one hand during use, meaning that you can hold the workpiece steady with the other hand. There were a few difficult patches of grain where I had to resort to some very localised sanding, for which I used Abranet 220 grit on a sponge sanding block. I’ve not used Abranet before, but after reading several glowing reviews I thought I would give it a try, and so far it does seem to be the best abrasive I’ve used. I blended the planed and sanded surfaces together using a cabinet scraper, which gave a consistent finish across the face of the board.
I then repeated the process for the top, with one significant diffence. With the end pieces I was able to work from the dovetailed corner down towards the feet. However the top is dovetailed at both ends. Planing off a dovetailed corner would chip out the end grain on the tails, resulting in plenty more clean up and patching. Instead, I worked from one corner, stopping an inch or so before the dovetails of the opposite corner. Then it was a matter of working in the opposite direction until both corners were flushed up and clean. A cabinet scraper helped to blend the transition between the two directions of working, and by lifting the scraper off the workpiece before I reached the very end, I was able to avoid any spelching.
As a final touch, I lightly chamfered the aris of the rear edge of the carcase, using the No.102 block plane. Oak is tough, but can be prone to splintering on the edges, and so removing the sharp corner helps to protect the edge from breaking.
With the three wide faces cleaned up, I decided to apply the first coat of shellac while the wood was freshly planed and scraped, to avoid the fibres darkening through oxidization during any delay to finish. I used the same 2lb cut of blonde shellac as for the interior of the carcase, brushed on with a 1″ Gramercy ox-hair finishing brush. The shellac brought out the grain and added a little pizazz to the dovetails.
All that remains now is prettying up the front of the carcase, applying the rest of the shellac and wax, and (most importantly) stamping the boot bench with my maker’s mark. More on that next week.