Watch the building process video
dec 2010
End Table Dog Crate (building process)
This is the building process for two end table dog crates built of solid cherry. Basically these are end tables that will be placed next to a couch, with the lower section being made for a dog. These tables where commissioned with the Windsor Chairs and Farm Table. These tables will have full frame and panel construction with a door on the front. The finish will match the farm table top.
First, we design and draft full scale drawings of the end tables to the customers specifications. Once designed, we start milling cherry for all the parts.
Parts are now milled to the correct thickness, now ready to be cut to length. After all the parts are cut to the proper length the joinery is laid out.
Once the joinery is laid out (mortise and tenon) the mortises are cut first followed by the tenons.
Each dog crate end table has 85 mortise and tenon joints, 170 total. Each joint is fit by hand to ensure a snug fit.
Below is a picture of the many parts ready to be fit.
Piece by piece, each section comes together, with adjustments being made to ensure tight fitting joints and shoulders. The left picture will be the front frame and door, while the right picture will be a side without the panel.
Next up, the panels are milled and glued. Consecutive boards are used on the panels to ensure color and grain matches. After the panels are dry, they are cut to size and marked to receive a rabbet. This allows the panel to slide into a 1/4” groove in the frame.
After the rabbets are rough cut around all four edges of each panel they are then hand fit to get a nice fit. Each panel is then dry fit without glue.
Next, all the machine marks are removed and the surfaces smoothed with hand planes and scrapers before glue up.
After all the surfaces are cleaned up it is ready for glue. First, all sections are glued up individually.
Once all the sides are glued up individually, all four sides of each dog crate end table is glued and joined together. After the glue dries excess glue is cleaned from the exposed surfaces.
After the glue dries, the edges that were joined are planed flush with a hand made plane.
Then small feet are shaped by hand. This small foot detail helps give these dog crate end tables a lighter more “furniture” look.
Next up, the doors are closely fit with a hand plane before the hinges are installed. Final door fitting is done after the hinges are installed.
Next, the wood for the top is carefully selected, paying attention to color and grain patterns. After the wood is selected each top section is glued.
After the glue has dried for at least one hour the tops are cut to size. The top is then surfaced with a cabinet scraper, hand plane, and card scraper. This cleans the mill marks from the wood and also gives the desired surface. These dog crates have a hand planed surface, matching the cherry farm table top from the same order.
Next, the edges are hand shaped. This gives the piece a handmade look with slight variations to the edges of the top.
Next, the door hinges are mortised and the doors are hand fit.
With all the hardware fit the next step is finishing. First, a water based aniline dye is applied and allowed to dry. After the dye is dry, multiple coats of an oil varnish finish is applied.
After four or five coats of finish the dog crate end tables dry for a few days before the final rub down, this puts the final sheen on the pieces. After the finish is complete the top is attached and the hardware is installed.
Now the end tables are complete and ready for delivery.
The finished end table dog crates are now on our portfolio page
