Well this week I started working on my Hall Frame reproduction. I decided to make a prototype on this one. This will help me test out my templates as well as get my inlay skills warmed up. Much like hand-cut dovetails and other techniques that require a certain amount of manual dexterity, router inlay is not something you want to jump into “cold”. And remember, prototypes make great gifts for family members!
This process started with the creation of a few templates from the original tracings and outlines taken from the original frame. These templates were then used to create the prototype in some alder stock I had laying around. Once the basic shape is established, I had to work out the joinery. These joints are nothing short of unusual at first glance. The only way I can think to describe them is “Inlaid half laps”. To make things a little trickier, the pieces are different thicknesses so that the inlay piece stands proud.
The details of this process will be covered in a future Popular Woodworking article, so I apologize for the lack of detail here. But I did want to keep you guys updated on the process since I think its pretty cool.
Looks great Marc (as usual!)
How do you find using the festool router with templates? I have read that there is a concentricity problem with them. What are your thoughts?
http://woodworkforums.com.au/s.....hp?t=86633
Cheers,
Carl
Not that I have ever seen Carl. In fact, I used to have a major concentricity problem with my old DeWalt. I realized this after numerous sets of machine cut dovetails that were always slightly off, no matter what I did with the setup. My first set of dovetails with my OF1400 solved that issue. If I am not mistaken, doesn’t Festool sell a mandrel of some kind that will help you get a perfectly centered guide bushing?
All that being said, I did not use a template or a guide bushing for this project. It was all free-hand. The little tear-drop shape is just too tight for a template cut.
Hey Marc this is nice. It’s looks kind of whimsical.
Very cool man! I love how the Green & Green style uses different thicknesses in the parts. It seems to give a piece depth. (if that makes sense) Thanks for the post.
Larry
My ESP is working…
Just knew you were going to make one after seeing the original. Your hands were shaking my guess. Very nice, can’t wait to see the final one when you build it. Great work Marc
Featuring inlays dovetails nicely with an inquiry I’ve been considering. Some inlay kits come with down spiral bits, some with up spiral bits. Freud’s kit comes with an up spiral. They state a down spiral can cause the 1/8th inch bit to break more often, getting hung-up in the saw dust. Do you have a comment?
Well, from a manufacturer’s standpoint, I can understand why they would want to sell up-spiral bits. Less broken bits means fewer replacements and tech service inquiries. And the results are usually “good enough”. But ultimately, the down-spiral bit gives the cleanest edge. And unless you are plowing through too much wood at once, you should never have a problem with broken bits. So if I were to make a choice, the down-spiral would be it.
For this project, I used a 1/8″ straight bit freehand.
Marc,
Its really looking nice – well you had a good look at the original Green & Green design. How are you going to do the finishing ? like always – a whiping varnish ?
kind regards.
Robby
Hey Robby. Not sure what I am going to do with the finish just yet. Maybe a water-based product….
And just to clarify, this is actually not a G&G design. It was designed by John Hall, one of the main builders of G&G projects.
Nice to know – i must have miss understood it.
Well it looks really nice – can t wait to see the final result.
:o)
Great prototype! I am learning more about Greene and Greene and like what I see. :-) I was wondering though, Is SUBWAY a new sponsor?????
I also enjoy your articles and videos through Popular Woodworking.
Ha! If I walk in munching on a $5 Footlong, then you know what’s up. lol
That is a neat looking frame. Can’t wait to see this project finished. I always love seeing pictures of someone’s project while still in the workshop. I get to see all the neat little goodies laying about. I especially like the tin of Renaissance wax. Classy.
Hey Marc, the only problem with that frame is that it better be holding the f#@*ing Mona Lisa because NO ONE is going to care what it’s holding. You could hang the frame on the wall empty and it would be perfect!
Looking forward to the PW article.
Really Nice! You’ve taught me something about Greene & Greene. Nice craftmanship. Looks like you are having fun!
Strong work my friend! I can’t wait to see the final product. How are you going to cut inset for the glass? Sometimes I route it after I glue up the frame and clean up the corners, sometimes I do it before on each piece, haven’t made enough frames to know which is best.
Disappointment…that’s all it is, a huge disappointment. No, no, not the frame, that’s wonderful. I am disappointed that you didn’t take the opportunity to call this “Hall of Frame”! I mean come on, what happen to the charm of word play we have all come to love from you? “Will the REAL whisperer please stand up”
(Boy, I hope you didn’t call it that somewhere else and I missed it…if that is the case then I blame it on my wife for distracting me!)
Sheesh! Everyone’s a critic! I have to come up with clever names for my regular blog posts too?!?! By the way, “Hall of Frame” is way too predictable. ;)
I read it as “Hall of Frame” initially, so that is too predictable…or my reading skills are that bad ;).
Look forward to the finished product Marc. This may have been addressed already, but what do you plan to “frame” with this project?
I actually have a special Gamble House print that I picked up at the Gamble House book store. Should be perfect for it!