I started a walnut writing desk a month or so back, and have documented the process in my video blog along the way. FLWoodRat asked me if I might be interested in also documenting my process here on the 207. While all of my footage thus far has been in video, I was able to grab some screen shots of the process along the way. Sorry for the long post, but I'm basically trying to catch up on 5 weeks worth of work in one post.

I started out doing some rough sketches, then a basic google sketchup model (http://sketchup.google.com/3dwarehouse/details?mid=ed2592a70e49a283f04a4560b57187d9&hl=fil&ct=lc) and then moved on to a full-size model made out of pink foam insulation.



Next I moved on to shaping the curved front rails and legs. I build a template and template routed the front profile, and then shaped the legs using the band saw and spokeshaves.




The next step was to selecting a nice piece of walnut that I could bookmatch for the twin drawer fronts. I made a cardboard "window" sized the same as the drawer openings so I could find the perfect grain pattern to use.



I then resawed the drawer front to get my matched fronts, and then used additional laminate strips over a bending form glued up with veneer glue to hold the shape. The bending form was made directly from the curved front rails to ensure the drawer profile would match exactly (as these are inset drawers).



Cutting the dovetail sockets in the curved drawer fronts was one of the most challenging aspects so far. Since the surface is irregular, it requires a rabbet cut into the back (done with a rabbet plane).




I was able to use the bending form again to help support and hold the piece while wasting out between the pins by hand.



The half-blinds came out fairly well especially given the added degree of difficulty with the odd angle, extra rabbet, and curved drawer front.


I've now got one drawer completed, and plan to have the second one wrapped up in the next few days so I can move on to building the top and doing some string inlay.

Good to see you here Rob! I have been following your videos. Very well done. Always really informative and thorough. Thanks for sharing here too!

Thanks Paul. I guess you could think of this as the Cliff's Notes version!

Rob
Drop me a PM about the EMGW you might be interested.

Rob,

Thank you for posting your project on our Forum. I asked you to do it for a couple of reasons. First, I've been following it on your blog and found it to be very interesting from your initial design discussion, through the use of a foam mock up to your progress on making the curved stretchers and drawer fronts. Secondly, it's an excellent addition to our 207 and exemplifies the quality work many of strive to reach as we develop our woodworking skills.

Keep up the good work.

Bruce

Nice!! I especially like the thin pin dovetails.

Insulation foam makes a good material for a mock up, I'll have to remember for next time. Are you building this for the expo?

Pink foam! Brilliant.

Saw that photo before I started to read. For a minute I thought you were making a "Hello Kitty" bow front desk...

i love the pink foam idea. That's one of those "why didn't I think of that?" sort of things. Definitely going in my idea file. Consider it stolen.

Paul
the little guy

My wife does want me to paint the final desk pink, but I think I'm going to have to overrule her just this once. The pink foam does work fairly well as it comes in 1" and 2" thicknesses. It's easy to mill on your regular power tools, and I found that double stick tape works best for joining. It doesn't last forever, but long enough to tweak your design. The only warning I'll offer is it does generate a good bit of pink dust in the shop - your friends may ask questions.

I did forget to mention this is a piece I plan to enter in the wood expo, so with any luck some of you might get to see it in person. Thanks again to Rat for encouraging me to post the project. Compared to editing video, posting photos is a piece of cake.

-Rob

Whaddya mean you "think" your gonna overrule her. You better Man-up and out right say "NO!!"

Disclaimer: my wife is not looking over my shoulder, so I have a free mind for 2 minutes.

I am the master of the house!

(at least until "she who must be obeyed" gets outta hospital)

Paul
the little temporarily single guy

You mean like the guy in Les Miserables?

It's been nearly half a century since I read the story of Jean valjean and his "pet police inspector". I don't get the referral.

Paul
the puzzled little guy

I was thinking the musical adaptation.(they say a 4 letter word so possibly not work safe) The part where his wifes sings

http://www.youtube.com/watch?v=SFPsEwV38Q0

I checked that link, and all I can do is laugh my derier off!

Paul
the little master of his little house guy

I finally completed the writing desk this week (just in time for submission to the Wood Expo) and I realized I was behind on my "in progress" photos. I left off having completed one of the drawers. I wrapped up the second drawer, and then built the runners, kickers, and doublers to hold the drawers. I used classic stub tenons to attach to the front frame, and cleats with half-laps to secure the backs.


Next, I spent quite a bit of time selecting and orienting my pieces for the top lamination. I went with quartersawn walnut for the top, so the widest pieces were only 7-8", so it took four boards. I oriented the grain to best accentuate the front curve.


I then moved on to the inlay. I used all hand tools from Lie-Nielsen for this process, both for cutting the stringing strips and the channel to receive the inlay. I found hand tools a lot less scary than using a router.


After a little boiled linseed oil, and filling the pores with many rounds of 2 lb. cuts of shellac and sanding, I finally got a nice flat finish on top. I chose some pendant pulls to complement the curves in the desk and came out with the finished product. This was one of the most satisfying projects I've worked on, pushing myself out of my comfort zone in a few different respects.

Awesome work, and a lot of good pointers Thanks for posting it

Rob,

Nicely done. I look forward to seeing this in February.

Bruce

Admirably done my friend, Take a bow, you've earned it!

Paul
the little guy

Rob
Very nicely done (and presented in your podcasts). I am curious if you would be willing to offer a post-mortem on the project? Is there anything you would do differently? Biggest lesson learned?

Very interesting question. The big "first" on this project for me was the bent laminated drawers. The biggest challenge I faced was that my drum sander is set up with the open end of the drum slightly higher so I can do dual passes on wider boards without leaving a groove. But that slight difference meant my laminate strips for the drawer front were slightly beveled side to side. Compounded by the six or so layers, the final lamination had a slight bow in the center (top to bottom). This created a bit of a challenge when dovetailing the sides in. In retrospect I should have set up the drum sander head to be perfectly parallel to the bed and this problem would have been eliminated. I also had issues starting the sander on 80 grit. The scratches were so deep in the figured walnut even the 150 grit couldn't remove them easily. I ended up doing a lot of work on the ROS to clear that up. From now on I'll start at 150 for anything but very rough thickness sanding. Fitting the drawers was also a bit tricky since the sides are different lengths. I really had to get the runners and kickers perfectly square to insure the drawers dont rack.
Aside from that the rest of the project went pretty much as planned/expected. The inlay was fairly easy and will be something I incorporate into a lot more work from now on.

I really like this Rob, and the videos on your Blog are great. The workbench worked out nice too. Oh Consider the foam idea nicked, thats a great way of designing different shapes without cutting into stock. Thanks for taking the time to document the build here too.