Wood plant

Some projects get completed quickly. Some projects take longer than expected. Then there are those projects that turn into epic journeys, full of side tracks, dead ends, new skills and maybe even a trip to the emergency room. The Shaker Cupboard was one of the latter.

Almost three years ago, my wife and I, along with our friends Dave and Sarah, visited the Shaker Village of Pleasant Hill in Kentucky. I didnt know it at the time, but I took the picture that would inspire this project. In the back of the Centre Family Dwelling, I saw this step-back cupboard:



About a year later, I decided to create my own version - based on the Pleasant Hill cupboard, but with modifications made to fit our needs. I made some sketches, some simple plans and got to work. I had no idea how long a project this was going to turn into. In the end, the cupboard, in various stages of completion, was in the shop for about two years. Obviously, I did not work on it constantly, or even consistently.

I didnt decide to take pictures of the process until it was already underway. My intention is that this will be a photo essay, and as such will be more images than words. Ill try to keep it to short captions at most.

Attaching the cupboard back: bench and tools (coins were for spacing the T&G boards).



Bench with tools and cupboard.



Cupboard with back complete.



Detail of adjustable shelf supports in lower section of cupboard - shelves get notched to fit around vertical supports.



Still life with hand tools (So I like pictures of working tools - gotta problem with that?)



Shelves in place.



Face frames installed - its starting to look real. I spent a lot of time making sure that the shelves could still be removed after the face frames and doors were in place. They can - just.



Frame and panel door mock-up.



Rail, stile and panel test joint. In the end I decided against the beading.

Playing with the mouldings for the cupboard - ovolo and cove.



Put together as a built-up profile.



Mock-up of crown moulding in place - I liked it, but it was to "colonial" for this cupboard.



A simpler crown moulding mock-up - better - but I would eventually remove the thumbnail top and just go with a simple cove moulding. This also shows a test of one hinge design - taped in place - I liked it, but in the end went with one that had removable pins - it was easier to work with.



Doors complete - final fitting with the planes.



Doors fit - the end is in sight!



Hinge work - and a new appreciation of the Stanley #95 butt gauge.



Close-up of chisel scoring of hinge mortise.



Finishing the mortise with a router plane.



Testing the fit.



Making pilot holes with awl - a sharpened finish nail chucked in old cobblers awl - the twisting motion seperates the wood fibers - I have more control than with a drill.



Lower doors hung.



Upper doors hung and knobs installed - I turned the knobs on my spring pole (shock cord) lathe - definitely the craftsmanship of risk - I need WAY more practice, and I think I should have used air dried birch rather than kiln dried pine.



Detail of knobs - the conflicting grain patterns wont matter once the cupboard is painted.



Speaking of which... milk paint of course - Union Blue from The Real Milk Paint Co. The cove mouldings had also been added to the top and the step.



And its done! "Make Way! Blow the trumpets!"

There are still a couple of tweaks needed. I dont like how bright the hinges are - one day I will dull them down a bit. And I might add a second coat of milk paint eventually, but that depends on how it ages... But for now we are very happy with it! And I am very glad to have it out of the shop and in the house! Finally!



A group shot of the tools used on this project. The two contraptions at the bottom are my shooting board and the main part of the treadle lathe (w/o treadle). Missing from photo: miter box.