Best Project wood

I stopped by Rockler the other day to pick up another Clampit.  I think putting together the first couple of supports on the hall tree would have been easier if I had 2 of them to clamp at the same time.  They also had the mini Clampits on sale for $4.99 so I picked up a couple of them as well.  If you look in the top righ corner of the picture you can see where I had the pocket screw split the wood.  I glued it back together and clamped it but now my wife wants me to stain it instead of paint it.  The screw is really close to the surface so I may just pull it out now that everything is glued together.  There is still a screw on the bottom half and I dont think it should come loose.

10/1 Home stretch on the door project ... We had to go to the site yesterday to final refit the front door before final priming,painting and rehanging. The molding miters will need some patch and fill work and Tom of Keefe and Wesner Architects (restoration specialists) turned us on to a product by West Systems called microballoons. You add this sort of mysterious powdery stuff to their epoxy and it makes what they refer to as a fairing compound. Weatherproof, durable, carveable, sandable, paintable .... We made a sample Tuesday and its pretty amazing stuff. More on that later ... Click photos to enlarge them.

The opening with its granite sill

The inside view after refitting ... There was soooo much paint on the jamb edges that the door was thicker than the rabbett in which it fits. Over the years, it seems that the carpenters, when repainting and adding new hardware, had rehung the door further and further from its original location until when we first fitted it yesterday, it was about 3/16ths pround of its jambs. Luckily, we were able to rerout the jambs in place and now it swings freely, fits flush and doesnt bind ... well add new weatherstripping after its painted and rehung.

From the outside with the new knocker in place
Update 9/22

Trevor has made one continuous patch to cover the historical assortment that has accumulated on the outside ... The new knocker will cover the old knocker holes .... the small patch was a knot that had fallen out ...

And weve laid out the Ball & Ball lockset location )love their stuff). Hell fill the round holes and do another one patch on the inside.
9/19/09
Another project were working on for the painted library house is the front door. Originally, our scope of work included making a new front door similar to the original. We didnt pay too much attention to the old one at first as it had some 1960s or 1970s era lacquered brass hardware and some really thick bad paint. But, when I decided to take the original door to copy it, we started to look at it more closely and decided that, yeah, maybe it was old and well strip it first and see what it looks like. I took it to my friend Alan Tschorn at Chem Clean in Arlington, Vermont and he put it in his dip tank for a soak. When we got it back, it showed some past insults, but it was definitely an old door. Were feeling like it could maybe possibly be the original after removing the moldings that were loosened by the stripping process. The panels are all one piece, not narrow glued up boards. Some are bookmatched (the two horizontal top ones) or obviously from the same board, and all the nails appear to be from the same period and manufacturer. Im actually not familiar with the exact style, but it appears to be an early cut nail, stamped from a sheet possibly by a local Vermonter. Check the nails out below ... Click the pictures to enlarge them ...

Interior view of the original entryway ...

On our first site visit, we took measurements to estimate a price to copy the existing door. This house has beautiful, original, cut granite foundations and note the granite sill detail ... You dont see that often ...

Back from the strippers ... interior view

Exterior view showing clearly the patches that accumulated over the years as hardware and locks were changed ..

The door with all its exterior panel molding removed. To get the first one out we drove the two nails holding the molding through and then pried it up. Once that one was out, the others could be removed with their nails ....

Paint and stripper remained under the hand plane shaped moldings

The nails ... two per strip of molding, 8 per panel, carefully and symmetrically placed by the original maker. Note the square ground nailset for setting the nails through ... Well patch the holes neatly, and make accomodtions for the new Ball and Ball hardware ... Itll be sweet when its repainted and Im sure it will be happy to get back home ....

OK ... Thanks everybody ... Ive gotten comments from my own blog and two other forums that I sometimes post on ... I will, (soon I hope), be writing a definitive policy that I can post on my website and link to as a warning if a design process seems to be getting out of control ... My problem with the situation below was that I KNEW it was out of control, but thought it was just one email aawy from resolution ... Been there, done that ... time for a change.

" New Design Fee Policy ... 5/31/09 "

" Over the years I have always considered the interpreting of my customers’ ideas, both potential and repeat customers, part of my job description, and, unless it was obviously going to be a major undertaking, (a library, a large entertainment center, a kitchen) a free service to them. In the past most of my customers came to me by word of mouth with some background from the person who referred them to me and this ‘free design’ policy was a fine one. With the rise of the internet as a referral tool, more and more people come to us, (thankfully), but with no introduction and no in person visit to our shop where they can plainly see the nature and scope of our business. As a result, sometimes the design process has the potential to get out of hand as it’s very easy to say, ‘I’d like an estimate on a coffee table sort of like this, but maybe like that … Nooooo.. that’s not what I had in mind …. ‘ in an email. I recently had a 34 email exchange with a potential client regarding a small project that sucked up an unbelievable amount of my time. It was a ‘rush’ job and I always thought I was just ‘one more email’ away from the resolution of it. I was so sure I even made sample inlays in abalone and mother-of-pearl before receiving a nickel from them. (WHAT WAS I THINKING?) Anyway, the process came to an ugly end and left me pondering how best to avoid this in the future. After a little more consideration, I will be probably be posting this policy to my website and will refer potential new clients to it if it seems appropriate.

Here’s what I’ll do for free :

Have a meeting or two of reasonable length, say an hour or so, at my shop or at their house close by …. No Charge …. More than ½ hour travel time from my shop, meetings MAY involve travel time reimbursement. The client will be informed in advance and the charge will be assessed at my discretion, probably depending on how the meeting seems to go.

Provide concept sketches and one CAD scale drawing … No Charge

If design is ‘close’ but not finalized, I’ll provided a non binding ESTIMATE of the project’s cost including shipping and installation. No Charge

If we move on from there without at that time, a formal agreement, I will request a non-refundable, but applied to the total cost, design fee that seems appropriate to the project at hand, most likely a two to four hour fee amount. If that is used up, we probably have a problem and we’ll have to take it from there with a new design fee agreement ….

I hope this is clear and that it will help both me and my customers to understand that design is not something that happens but is a sometimes complicated and time consuming process. And, time is really all we’ve REALLY got.. "

Here are the other comments ...
UK Workshops .. Project,Shops and Pat Mistakes Forum UK Workshops
Fine woodworking Knots Forum

ORIGINAL POST starts here ...

Ok .... Id really appreciate some comments here. I recently had a potential customer who was referred to me by a fellow woodworker and friend. She wanted to have a special table made and was in kind of a hurry... in the next month I believe were the words in her initial email. My friend thought I would be perfect for the job as I have several employees, try to be flexible with my scheduling and enjoy the kind of inlay work she said she was interested in. Time was short so I sent her some sketches. Then I sent her some CAD drawings. Then we went back and forth and back and forth until my inbox looked like this (click the photo to enlarge it) ...
and my sent messages had 14messages sent to her, AND, I have a different computer at work where I was also sending messages regarding this project. I thought the design concept could be cool and I was interested, but she was not interested in any wood except quilted big leaf maple and was stunned by the cost (as was I) of solid wood in that species. So, I said I would try to do an inlay in the commercial veneer she liked. Typically if we are inlaying abalone in veneer we make our own 1/8" thick veneer so we can actually sand the in lay after its stuck in there. . Commercial veneer is only a 42nd of an inch thick so theres not much room for sanding. Then, I cant believe I actually did this without a deposit, but I made a sample inlay (above) (from her photo) to see if we could do an abalone inlay in commercial veneer and Trevor pulled it off. In the end it all went bad. She said she mailed me a check from in state on a Wednesday, and it hadnt come by the following Monday, plus, I had some normal jobs com in in the meantime, (meeting, drawing, check) plus, she no longer liked my cattail design, which I copied from the photo that she sent me and the inlay was the wrong size ... By that time, I couldnt order the veneer and get the table done in time so I told her I could do it later when we had more time to work on the design, or cancel the job and send her check back minus a small design fee. Well she flipped out on me and stopped payment on the check !.... What do you all think???? Big, complicated jobs, no problem ... We do a little design work for free and then were on the clock. Smaller jobs, (1000-5000),at what point does the designer bring up a design fee ??? After the first sketch?The second. third or 10th email? After thirty years I should have a handle on this, but, I admit, I dont. Design is the fun part of it for me and I like to think Im pretty quick at it so normally its not a problem on a smaller job. But, occasionally, and more often lately, with inquiries from the internet and the economy not so robust, it seems like I (we ALL) should have some kind of policy to cover instances like this .... Comments anyone? Please ....

My first email response

Her dragonfly pushplate photo and my drawing over it

My first CAD drawing

The final folder before the end ....