Keith Johnson takes us through a captivating journey of crafting modern floating nightstands adorned with brass and epoxy inlay.
This project not only showcases his woodworking skills but also highlights the importance of precision and creativity in furniture making.
Getting Started: Designing the Nightstands
The project kicks off with the selection of materials. Keith begins with two panels of walnut, each three-quarter inch thick and about 60 inches long. These panels will form the base of the nightstands.
Before diving into construction, he emphasizes the importance of planning and layout to maximize the wood’s natural grain patterns.
After laying out the parts, Keith makes miter cuts for the nightstand boxes. He carefully measures and marks the wood to ensure that the cuts are precise, aiming for a 45-degree angle. This attention to detail is crucial for achieving tight joints that will not only look good but also provide strength.
Joinery Techniques: Strengthening the Structure
One of the key aspects of this project is the joinery. Keith opts for Lamello’s Zeta P2 and Clamex P14 connectors for a strong, precise join. While these tools might be an investment, Keith assures that there are several alternatives available for those on a budget, such as dowels, biscuits, or splines.
Using these connectors allows for a clean assembly process without the need for clamps. Keith demonstrates how to ensure that all joints fit snugly before the final glue-up, which he completes using Total Boat’s Thixo thickened epoxy. This epoxy provides a longer working time, allowing him to manipulate the pieces without the pressure of a fast cure.
Creating the Drawers: A Focus on Functionality
Once the nightstands’ cases are assembled, attention shifts to the drawers. Keith cuts the drawer components, ensuring that they fit the predetermined dimensions. The dimensions of the drawers are determined by the opening of the case, which is a critical step for ensuring a smooth operation.
Keith utilizes Blum under-mount slides for a sleek and modern look. He carefully measures the necessary depth and width of each drawer to ensure a perfect fit. The use of a stop block on the table saw helps him achieve consistent cuts across all parts.
Crafting the Unique Drawer Fronts
One of the standout features of these nightstands is the drawer fronts, which incorporate a stunning brass and epoxy inlay. To create this effect, Keith embarks on a road trip to visit his friend Paul at Copper Pig Fine Woodworking. Together, they utilize a CNC machine to carve a modified Asanoha Japanese pattern into the drawer fronts.
Using a 3/64″ spiral downcut bit, they achieve clean cuts that are essential for the inlay process. After carving, they mix brass powder with epoxy, which is then poured into the carved patterns. This meticulous process highlights the artistic side of woodworking, allowing for creativity to shine.
Finishing Touches: Sanding and Applying the Finish
After the epoxy cures, Keith returns to his shop to trim the drawer fronts to size and prepare them for finishing. He employs a meticulous sanding process, moving through various grits to achieve a smooth, polished surface. Keith emphasizes the importance of sanding in the direction of the grain to avoid scratches.
Once the surfaces are prepped, he applies Rubio Monocoat walnut finish. This finish not only enhances the beauty of the walnut but also provides a durable protective layer. Keith’s method involves applying the oil, letting it sit, and then wiping off the excess, ensuring an even application across the surfaces.
Installing the Drawers and Final Assembly
With the nightstands nearly complete, Keith focuses on installing the drawers. He uses a combination of spacers and double-sided tape to position the drawer fronts accurately. This method allows him to achieve a consistent reveal around each drawer, ensuring that they look professionally finished.
For the final touches, Keith installs French cleats for mounting the nightstands on the wall. This method provides a clean look and maximizes floor space in the bedroom.
However, an unexpected disaster occurs during installation, leading to a moment of panic when one of the nightstands falls off the cleat.
Lessons Learned: Reflecting on the Process
Despite the mishap, Keith reflects on the entire process with a positive attitude. He highlights the importance of learning from mistakes in woodworking. This experience serves as a reminder of the unpredictability of working with materials and the value of patience and precision.
Conclusion: A Beautiful Craftsmanship Journey
Crafting the walnut floating nightstands with brass and epoxy inlay not only showcases Keith’s woodworking abilities but also his creativity and problem-solving skills. The combination of traditional woodworking techniques and modern design elements results in a stunning piece that adds character to any bedroom.
As Keith concludes his project, he reminds us that every piece of furniture tells a story, and every challenge faced along the way contributes to the growth of a craftsman. With a total material cost of approximately $490, these nightstands are a testament to the beauty of handmade furniture.