Successful Delivery — It's a Buffet!

Before we take a look at the completed mahogany buffet, I want to show you some of the work that went on during the final week.

Because of the asymmetrical shape of the pulls, I needed to come up with a clamping caul that would hold the pull in position while the glue set up. I first cut a trough into the bottom side of a piece of maple and a pointed edge along the top. The pointed edge is there to align the clamping force with the tenon. I then proceeded to fill the cavity with hot melt glue, while protecting the pull from damage with a couple layers of plastic food wrap. By letting the glue cool for a bit, I was then able to press the pull into the trough without damage from the heat. This created a form-fitting caul that ensured the pull would not be damaged or pulled out of alignment by the clamp.

Next, I fitted the floating tenons to the mortises.

And with a block plane, fitted the pulls to the drawer fronts. The new clamping caul came in handy for this, too.

The position of the clamp was then adjusted until the pull was held in its intended position.

While that glue cured, I installed the drawer bottoms with brass screws that engaged with the drawer backs.

I made a similar clamping caul for the door pulls which are asymmetrical in two directions.

Last, but not least, I spent a day in the living room, cleaning up the piece and getting it ready for delivery.

I really enjoyed this project. It combined the challenge of reproducing design elements of existing pieces in the client's home with managing a large size project in my small studio.

Other than having a bit of ice on the sidewalks, last Saturday was a perfect day for delivery of this piece. I was lucky enough to find help from two kind and generous souls, so with a little care and planning, even at a hefty 190 pounds (the cabinet, not me; my weight is classified), the delivery went as smooth as silk.

Click here, or on the image below to view the complete gallery of buffet photos.

I'm grateful for the opportunity to make the buffet, but am now looking forward to the next project. I have several pieces in the queue with many more interesting challenges ahead. I hope you'll stay tuned.

Hej då and happy shavings!