Here you had an “all assembly needed” flat pack book case and stick chair. TIme to turn that stack of maple into something useful.
Since the start of the year I’ve had the stock for my boarded bookcase stickered neatly at the side of my desk, underneath the timber for a Welsh stick chair. The bookcase design (from The Anarchist’s Design Book) is one I’ve been looking forward to for a long time, as it looks like a fun build and will liberate a lot of my history and woodwork books from the boxed purgatory they have suffered since we moved house. I decided to build the bookcase out of maple to match the Staked Work Table I finished in January.
Removing a live edge from the maple seat
Unfortunately sourcing wide enough boards in the UK seems to be a challenge, so I’ve committed to gluing up a pair of boards for each of the sides and the three shelves in order to reach the 13″ width needed (a reason, perhaps, to move to Kentucky? I hear that such boards are in plentiful supply). If nothing else, this will give me plenty of practice with long edge joints, which is always good to have. The other project on the to-do list is a variation on the Policeman’s Boot Bench for our hall (in pine), which I promised Dr Moss I would finish before our annual Christmas Tree trimming in early December. I’ll be starting the boot bench in October, so I thought that I would use the remainder of September to build a steam box so that I could finish off the Apprentice’s Stick Chair, and also start gluing up the panels for the book case. . Although I don’t normally move between several simultaneous projects, I will be staggering the bookcase build in between stages of the boot bench and hopefully doing so will be a positive experience.
A stick chair seat in the clamps
While I was thinking about working on several projects at once, and had the glue warming in a mug of hot water, I decided to joint up the seat blank for another child sized Welsh stick chair (and now I’m thinking that the autumn is looking very busy!). This chair will be all maple, and be a little different to the one I am building for the Apprentice. The 2″ thick maple seat was made up of two boards, and jointed very easily before going in the clamps to cure over night.
Laying out the mortises for the
While I waited for the glue to cure I finished making the chair pattern I started a few weeks ago. While I’ve made plenty of guitar templates, it is not somthing I’ve done for furniture. For chairs it makes a lot of sense as there is a great deal of construction information to collate if you want to make another version of the same chair (and I do) – mortise positions, resultant angles, sight lines, seat dimensions and curves. I intend to use this pattern as an aide memoire rather than a concrete design to follow slavishly – this way all of the information I need is in one place, but I can still change the details and proportions as the whim takes me. The pattern is on 6mm ply, which means that it was easy to work but should be durable for years of use.
With the pattern complete and the seat blank clamped up, I decided to get a start on jointing the first side of the bookcase. I started off by levelling the rough sawn edges with a No62 plane that I’ve been testing for an article in Furniture & Cabinet Making. The No62 is shorter than I would like for a 48″ long edge joint, so I then moved to my usual No8 jointer. I quite enjoy edge jointing – the Staked Work Table build was good training for long edge joints, and I was looking forward to the practice of jointing five pairs of boards for the book case. Maple can be an unforgiving wood to edge joint – being very light in colour the glue line can be glaringly obvious unless you get a good tight joint off the plane, without relying on clamp pressure. The key (as with many woodwork operations) is patience.
Jointing the first set of boards for the bookcase
Unfortunately, by the time I had a good clean joint the temperature had started to fall, and while the glue was good and warm in the pot (I warm Old Brown glue to the recommended 120-140F), it started to tack up while I was pulling the top board into position and setting the clamps. It was now 13C in the ‘shop, and I wasn’t confident that I would get a good bond with the temperature dropping so rapidly. Removing the clamps and washing the jellified glue off both halves of the joint wasn’t how I had intended to spend the late afternoon, but you only get one chance to nail a glue-up. With the joint cleaned and dried, I moved the clamps and timber into the house (which was mercifully warmer) and had a much less eventful glue-up in the kitchen. It is definitely getting to the time of year where any ‘shop glue-ups have to take place earlier in the day, or else in the house (another reason to move to Kentucky, perhaps?).
Over the next couple of weeks I’ll move my way through the stack of maple in the music room waiting to be glued up into panels for the bookcase, and will also progress the maple stick chair (as well as building a steam box and finishing the Apprentice’s Stick Chair. There’s a fair amount going on!). Juggling multiple projects will hopefully teach me a few valuable lessons, as well as watching various things take shape.
The aborted glue-up in the workshop. just before I moved everything into the house to work at a temperature much kinder to hide glue