In the world of woodworking, every project begins with a vision. Keith Johnson takes us through a remarkable journey of transforming a non-functional space into a luxurious built-in for a former musician and audiophile. This project showcases not just craftsmanship but also the intricate planning and execution that goes into creating a stunning piece of furniture.
Understanding the Project Scope
Every bookcase starts as a set of boxes, and every desk is a series of boards. However, when luxury meets necessity, a non-functional area can be completely reimagined. The client’s request for audio components integrated directly into his desktop sent the project costs soaring, leading to a series of challenges. The first step involved obtaining accurate on-site measurements before moving on to shop drawings.
Initial Planning and Measurements
To kick off the project, Keith collaborated with his friend Kevin from Fineo Cabinetry, who brought along his laser and iPad for precise measurements. This resulted in perfectly dimensioned 2D drawings created in SketchUp. Despite the straightforward nature of the build, one particular element, the angled audio cabinet, posed significant challenges. Once the client approved the plans, it was time to gather materials.
Gathering Materials
The wood chosen for the floating desktops was 84 Walnut, which would ultimately be an inch and 3/8 thick. Keith posed a fun challenge for viewers, asking them to guess the material costs. As the build progressed, he shared individual costs, revealing shocking figures along the way.
Preparing the Wood
To ensure stability, Keith decided to rip down larger planks and glue them back together. This method not only provided more strength but also addressed the cupping in the wood. After face jointing and planing, he moved to break down some walnut veneer plywood, which came with a hefty price tag of $250 per sheet. This moment was a wake-up call for many woodworkers watching.
Grain Pattern Layout
One of the critical aspects of the project was the careful layout of the grain pattern for the cabinets. Keith wanted to ensure that the cathedral grains were centered, avoiding a haphazard appearance. This meticulous attention to detail was vital for achieving a cohesive look in the final product.
Gluing the Desktop Panels
Keith spent considerable time selecting the best grain pattern for the desktop, ultimately deciding on the most visually pleasing layout. He opted to glue up the boards in two sections for ease of handling and stability. After gluing, the panels were run through the planer, and the two sub-panels were glued together for a solid finish.
Building the Cabinets
Once the desktop was prepared, it was time to focus on the cabinets. Keith began with a complete dry assembly of all the cabinets to ensure proper sizing for the face frames. He also glued up double-thick fixed and adjustable shelves, utilizing a glue applicator roller for efficiency. This step highlighted his preference for tools that enhance productivity in the workshop.
Using Lamello Connectors
Throughout the build, Keith employed lamello connectors for several reasons. Firstly, he wanted to avoid visible fasteners, which would detract from the overall aesthetic. Secondly, the design required double-thick cabinets to accommodate the face frames, which meant careful planning for the connectors was essential. The lamello connectors allowed for seamless joins that would remain hidden from view.
Finalizing the Cabinet Assembly
After assembling the cabinets, Keith focused on the face frames. Each piece was meticulously sanded flush with the cabinet parts. He also added a tiny roundover on the back of the face frame, creating a subtle shadow line that enhanced the finished look. This attention to detail was a testament to his craftsmanship.
Creating the Audio Cabinet Insert
One of the most challenging aspects was constructing the audio cabinet insert. It needed to accommodate three audio components on each side while maintaining a clean appearance. The insert was designed at a 30-degree bevel, requiring precise measurements and cuts to ensure everything fit correctly. Keith’s experience and attention to detail were crucial in this stage of the build.
Installation Challenges
Installation was not without its difficulties. Keith faced issues while installing floating brackets, which involved working around spray foam insulation and existing wiring. After two long days of installation, he managed to secure the brackets, allowing for a sturdy desktop setup. This part of the process emphasized the importance of preparation and adaptability in woodworking projects.
Finishing Touches
With the structure in place, it was time to apply the finish. Keith used a multi-step LED finish to achieve a rich walnut color while ensuring durability. The application process was efficient, allowing him to coat all surfaces in a fraction of the time traditional finishes would require. This modern approach to finishing showcased the evolution of woodworking techniques over the years.
Final Assembly and Adjustments
Once the finish was dry, Keith moved on to the final assembly. He meticulously secured all components, ensuring everything was level and aligned. The installation of the audio components and desk lights added the finishing touches to this luxurious built-in. Each element was thoughtfully integrated, reflecting the client’s needs and preferences.
Conclusion and Cost Analysis
As the project wrapped up, Keith revealed the total material costs, which many viewers found surprising. His commitment to quality and detail not only resulted in a stunning piece of furniture but also showcased the value of skilled craftsmanship in the woodworking community. This project serves as an inspiration for woodworkers everywhere, proving that with time and dedication, even the most complex builds can come together beautifully.