Barnsley Reproduction Build

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Blog series by stevo_wis updated 02-15-2016 09:55 PM 26 parts 47280 reads 52 comments total

Part 1: Starting

11-05-2014 12:51 AM by stevo_wis | 1 comment »

Fine Woodworking Magazine published an article many years ago of a table that Sydney Barnsley built in the 1920’s.The table is now in a museum in Cheltenham England. The article had original drawings that I redrew in Sketchup.I traveled to England last year to see the original and I have just procured some old white oak barn beams that I am going to use for the undercarriage. The table fascinates me and will require a lot of hand work and chip carving.It may take a while, but I wi...

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Part 2: Preparing the Legs

11-05-2014 03:22 AM by stevo_wis | 0 comments »

I rough cut the oak barn beams, jointed, planed the four legs and let them sit overnight. After marking out for stretcher mortise, beveling the edges, and turning the pads on the bottom of the leg I headed to the mortiser. I don’t have a 7/8” mortise chisel, and I also wanted a very clean mortise as the tenon is a through tenon. What I did was to use a 3/8” chisel and stayed away from the scribe line. I then went back and cleaned up the mortise by hand with a chisel. ...

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Part 3: Laying out Chip Carving

11-05-2014 09:32 PM by stevo_wis | 0 comments »

My next task is to chip carve the bevels on the four legs. The diamonds are 1 1/64 across the diagonals. The 1/64 was needed to ensure that the top and the bottom were a half diamond. Since the carved area is 25 3/8 long, by carving 25 diamonds each a little over 1” I avoided a partial diamond. I printed the pattern and glued the paper on to the legs and plan on just carving through. Since my printer can only print up to 11 inches, each pattern was made of three pieces. I enlist...

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Part 4: Starting Chip Carving

11-07-2014 04:29 AM by stevo_wis | 3 comments »

My last photos of my paper layout were hard to see, so I shot them again and have also included a practice piece to show what I am trying to accomplish. The triangles that are removed have no depth at the base of the triangle and the chip is removed down 1/8 at the apex. I have done a little chip carving with a knife into soft material before. For this project however, since it is white oak and I wanted to make sure my lines were straight, i decided to chip carve with a pair of benc...

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Part 5: One Leg Carved, on to the Frame

11-24-2014 03:46 AM by stevo_wis | 0 comments »

I finished carving one leg with all but the tenon at the top. The carving went well and turned out great. I will carve the rest in my spare time and will use shop time to build the frame which supports the table top. The view here if from the bottom looking up under the top. Each of the pieces are 3 1/8 wide and 2 1/2 thick. The joinery is draw bored mortise and tenons. The tenons are each 2 inches wide and 3/4 thick and present a challenge as most of the joinery is at 45 ...

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Part 6: Mortising Guide Block

11-25-2014 03:50 AM by stevo_wis | 2 comments »

I have 16- 45 degree mortises to chop in the frame and the stretcher for this table. I made this guide block and the photo below shows the half assembled block with the two angled guides that I will chisel to. The small block with the holes in it are a drill guide that I will use to drill out waste before chiseling. That guide will be slipped into the block loosely and after drilling it can be pulled out for chisel work. I am hoping that the drill guide holds up but I have a buddy who sai...

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Part 7: Frame Layout Complete

11-27-2014 04:24 AM by stevo_wis | 0 comments »

Most of the layout is complete for the frame parts. I did not do the button holes or the curved ends of the diagonal pieces yet. My thinking is that I want to get all of the mortises finished, then go back to cut everything to length, make the tenons and curved ends, button holes, and finally bevel the lower frame edges. It is really helpful to have a full size drawing, as no measurement is needed, I just had to transfer from the drawing to the actual blanks. The mortising guide block fro...

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Part 8: Still chopping, here is what I am building

11-29-2014 12:41 AM by stevo_wis | 1 comment »

Someone mentioned that she liked the blog, but didn’t know all of what I was talking about. With that in mind, here is a picture of the model from below. I am working on the frame that is just under the table top and is at the top of the legs. I am currently chopping mortises and while the jig works well, there is still a significant amount of hand chopping and there are eight mortises to chop. When that is done, I will finish cutting to length, cutting tenons, diagonal ends, mo...

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Part 9: Mortises are finally finished

12-13-2014 09:23 PM by stevo_wis | 0 comments »

The diagonal mortises were much more work than I expected. That plus a busy work schedule and holiday made for slow going. It took a very long time to chisel out the sharp points of the mortise and the hard oak was tough on my chisels. While the guide I made worked pretty well for the finally trimming, I found that it helped to use a small bit and drill out the four corners freehand to save a quite a bit of chopping. My drill went outside my layout line in the photo, but this will be cov...

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Part 10: Straight Tenons Finished

12-16-2014 05:05 AM by stevo_wis | 2 comments »

I am almost finished with the straight tenons that go through the end pieces of the frame. Almost, in that the ends will be shortened and beveled, but I will hold on that until the entire frame is ready to glue, so that they don’t get damaged until then. The two tenons are very straight forward but they do show and I took my time so that there were no gaps. First I just nibbled away at the cheeks with my table saw. After I sawed the cheeks, I used a handsaw to cut the shoulder...

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Part 11: Diagonal Tenons Almost There

12-24-2014 03:57 AM by stevo_wis | 3 comments »

The diagnonal tenons can be shaped on the table saw almost identically to the way a 90 degree tenon would be made. I cut the inside cheek cut very carefully and then quickly nibble out to the tenon’s tip.Because the shoulder will hide where the tenon actually enters the mortise, i can cut the tenons to width with the bandsaw. The tenons can slightly narrower than the mortises as they will match up to end grain which gives little glue strength, and they are covered in any case. after ...

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Part 12: Final Fitting and Draw Boring

01-04-2015 01:40 AM by stevo_wis | 2 comments »

I wasn’t satisfied with the fit that I talked about in the last entry so I called my mentor Dick. Dick is the best sharpener, dovetail cutter, and jointer that I know, and he came over. The two sides went together but still had a gap of 1/16 in a couple of places. After a while, Dick thought that I needed a miter jack or we could make one. So we made essentially a guide that wrapped the work piece on three sides to guide a chisel. Shaving very fine amounts and pushing the chisel at...

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Part 13: Button mortises, Final shaping, and Bevels

01-06-2015 05:03 AM by stevo_wis | 0 comments »

I am almost done with the frame. Below is a shot of what the frame will look like. I recruited my grandson Phin to run the mortiser. There are lots of them in the sides for button holes and one for each of the legs to fit into. The ends of the frame are cut with a nice gentle S curve. Two lines are drawn on the pieces because the S curves also need to be beveled. Nothing leaves a better finish than the drawknife and it is very enjoyable. No sandpaper her...

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Part 14: Gluing up the Frame

01-14-2015 03:51 AM by stevo_wis | 3 comments »

I was finally ready to glue up the frame. It happened that my friends Terry and Kris came over and were there for the glue up. The joints really can’t be clamped easily, but the 3/8” pegs and the offset in the draw bored holes pulled it together. I whittled a oak spindle down to about 7/16” in diameter and then drove it through a steel plate that was drilled at exactly 3/8”. I forgot to take a picture of the dowel making, but will include one later. After ...

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Part 15: Legs Trimmed and Installed

02-01-2015 03:35 AM by stevo_wis | 2 comments »

I mentioned last time that I would show how I make my dowels for drawboring. I use a drawknife to get them to about 1/2 inch in diameter and then pound them through a dowel plate. First I make sure that they go through the 1/2” diameter hole, then finally to 3/8” finished size. I bought the plate and it works well, though Roy Underhill says to just take a plate of iron and drill through them and leave any ragged edges on the plate’s holes to help cut the dowel. It was ti...

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Part 16: Making the Table Top

02-17-2015 03:25 AM by stevo_wis | 3 comments »

My friend suggested that we take a intermediate cabinet class at the local technical school. I had attended such a class many years ago, and even though we both have nice shops and have been woodworking for a long time, we signed up. The class workshop is almost brand new and full of state of the art machines including several saw stops, a 10 inch jointer, an unbelievable sliding table saw, and a 42 wide belt sander. The instructor is good and the students all seem great and all are at...

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Part 17: Top is Flattened

03-04-2015 02:49 AM by stevo_wis | 6 comments »

I was able to take my top to the night class I have been attending. They have a beautiful wide belt sander. It has two belts and it was set up with 120 and 150 grits. Before sanding, i just hit the high spots with my Bedrock 606. The machine is very accurate to the point where the second belt is set just a few thousands deeper than the first belt so that it grinds out the grooves from the rougher grit. It only takes about 8 thousands of an inch per pass and it took about five passes on e...

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Part 18: Back to The Stretcher

04-06-2015 01:45 AM by stevo_wis | 1 comment »

It has been a while since I posted, but I have been working on the lower stretcher that connects the four legs. This is a repeat of what I did with the frame but the stretcher has a few additional features. The stretcher through mortises pass through the legs and since the joinery all shows it must be precise. In addition, the hayrake portion of the stretchers have curves cut into them which makes the glue up a bit more challenging. I am keeping the work pieces rectangular as long as po...

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Part 19: template for butterflies

04-26-2015 02:58 PM by stevo_wis | 1 comment »

I am been working very hard for the last month at my day job (have to knock that off), and so progress has been slow. Our guild als0 had a sharpening day yesterday with Dick Christensen showing handsaw sharpening as well as chisel and scraper sharpening. Dick is the best sharpener that I know. All of that plus spring coming and firewood cutting beckoning makes it tough to work on the table and I also picked up a second 8 inch jointer which is another long story. I have the stretcher all c...

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Part 20: Slight Delay Via Nottingham

06-02-2015 07:17 PM by stevo_wis | 2 comments »

My friend Terry and I attended the Bodgers Ball in Nottingham England a couple of weeks ago. Bodgers are the guys who go into the woods and turn chair legs with spring pole lathes. While this doesn’t have a lot to do with the Barnsley table, we did stop and see the original table in Cheltenham, but not before we headed to High Wycombe which is north of London a short drive. High Wycombe was the center of chairmaking around the turn of the 20th century turning out upwords of 4700 ch...

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Part 21: Robin Hood and Little John (Bodger's Ball Part 2)

06-24-2015 12:00 AM by stevo_wis | 2 comments »

Little John (Terry) and I headed out to the Bodger’s Ball on the Saturday morning of our trip in Walesby, just outside Nottingham. Terry was hoping to find a bow and several arrows to try some archery, but of course, I only needed two arrows.There was a large marquee (tent) that held a lot of the contest entries, vendors, and auction items. There were also many folks set up outside with tents and caravans. There were probably 400 total people there and I am told that attendance doubles...

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Part 22: “A Horse, A Horse, my Kingdom for a Horse”. (Bodger's Ball Part 3)

07-22-2015 02:10 AM by stevo_wis | 2 comments »

“A Horse, A Horse, my Kingdom for a Horse”. Terry and I left Nottingham after the Bodger’s Ball and Liecester was right on our way south. Richard the Third was uncovered during construction of a parking lot last year. DNA testing plus the fact that he had been beheaded and had a hunch back proved that it was in fact Richard who had been buried for several hundred years after dying in battle. A new burial place was constructed in the Liecester Cathedral and it was dedicated ...

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Part 23: Assembling the Stretcher

10-05-2015 02:54 AM by stevo_wis | 4 comments »

It has been a couple of months since I have posted but I have been slowly coming along with the Barnsley Table. The stretcher had a lot of carving and bevels, but they are finished. It had some interesting joinery issues as well. The stretcher has almost the identical joinery that the upper frame has. I made one change here to simplify construction and that was to not have an acute point on the tenon. The pencil is pointing to the squared off tenon. Doing that made the mortise much ...

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Part 24: Assembling and Gluing the Undercarriage

10-12-2015 02:59 AM by stevo_wis | 3 comments »

I have glued up the undercarriage, which includes everything below the table top except the buttons holding the top on. The top of the leg where it is mortised into the top frame, and the mortise and tenons where the stretcher goes through the legs are draw bored. I applied glue and used a draw boring alignment pin to pull the joints as tight as possible and then also put a clamp across the joint to hold it when the pin is removed until the dowel is driven through. I glued and assemble...

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Part 25: A Bucket O’Buttons

11-12-2015 04:32 AM by stevo_wis | 4 comments »

There are 22 buttons that hold the table top to the frame underneath the table. They are approximately two by two inches and have these nice little bevels and wedges on the edges. Rather than work with very small pieces, I decided to make strips of them, do what I could on a machine, cut them apart, then finish each small piece by hand. The x’d out areas need to be hogged out and then cut between buttons. My radial saw seemed to be the safest and easiest tool so that I coul...

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Part 26: Butterfly Mortises

02-15-2016 09:55 PM by stevo_wis | 5 comments »

Butterfly Mortises I know it has been a while but I am finally back to my table build. The top of the table has 20 butterflies mortised into the top. In the original piece, these went all the way through the top and may have actually helped to hold the top together, but it is more likely that they were probably just decorative, as Barnsley has used them in several pieces. My friends all warned me that it would be much better to just rout a quarter inch deep or so, as going through ...

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