Boot Bench Part 1

Last week saw the start of my newest project; a commissioned boot bench. Taking inspiration from the clients current Ercol Stacking chairs, I designed a small bench for their hallway with incorporated shoes storage. This piece involves a lot of fine details and angles so I have spent a long time drawing it up to make sure the measurements are as accurate as possible.

Two days have been spent bashing out the turned components which has been great fun. I had to act fast to make sure I get the lengths and dowels turned before any movement in the wood occurs and puts my measurements out of whack.

I was lucky enough to bag some stunningly clean 1 1/2" Oak, fresh from the kiln. The nature of it has made the turning a little easier, so as not to have to think of nasty grain changes and off putting knots. The finish will need plenty of sanding to get a nice soft-touch feel, but thats part'n parcel with the nature of Oak, I guess.

Remembering the lakes

It had been 8 weeks of work, so I thought I'd spoil myself and take the bank holiday weekend off. Two days of walking and wild swimming, I felt so relieved to be out in the fells again. And ashamed that I had to remind myself of how beautiful it is here.

Going metal

I've been scrap-yarding. A friend of a friend has a whole bunch of rusty, old metal ripe for the picking. It's a treasure trove of tractor parts, ancient, dis-used agricultural equipment and other bits n bobs. I was like a kid in the sweet shop. It's amazing to see the quality and weight of how things used to be, and the shapes and details of some of the cast pieces are beautiful.

My imagination was going nuts, I wanted to leave with EVERYTHING. Thankfully, my friend reined me in. I settled for an early 20th Century cast window frame and began plotting an experimental piece that'll be my first welding project.

The lovely fellas at the steel engineering place sorted me out with the lengths for the framework. Ideally I wanted old stuff so it had the rusty, aged texture, but we couldn't find enough. Not a problem, we came up with an idea that may, or may not give the desired look.

So, after a few practice runs I pounced on squaring up the right pieces and welding them all together.

After the last bit of finishing touches, the frame was finished. By next week, it should be back at the workshop for the next phase...

Shakers history lesson

For the past couple of weeks I have been catching up with a friend to drool over magazines and websites in the search for just the right look for her new kitchen. It's been fun letting my imagination run wild about a space again, and not just an object. Thinking of alternative textures and colours wasn't really something I could do with my previous companies clients. However, with Kate its been more of a girly chin-waggle about what-ifs. The tight budget and dread of the last-resort B&Q bailout kitchen has, I think, allowed both of us to think of exciting, out of the ordinary sources as well as useful design additions for a busy family space. The wealth of scrapyards with rusty old agricultural machinery dotted all over the county is like my dream treasure trove. Luckily Kate is the perfect client and knows the exact, practical necessities her dream kitchen must have.

And so, after a gin fuelled meeting, we came to the conclusion that, for all aesthetic and practical purposes, the Shaker style was the way forward. But what does Shaker mean? Why does it conjure up images of religious sect uniforms and introvert communities?

I happen to find a book in the Office...

The Shakers

What a fascinating history! Reading only a little way in I knew that I had the Shakers all wrong and that their story is worth knowing.

Firstly, it all started with a British woman, Ann Lee. Now you've got to remember that the early days of this story is set in the mid 1700's. Equality, fair wages, trade unions etc, the words probably didn't even exist. For a religious movement, fronted by a woman with very outrageous views for the time to get any attention is an achievement in its self. But after moving to America, in the ten years before her death, the Shakers bloomed and formed full-on communities during industrial revolution, civil war and economic unrest. They had some pretty strict rules, including no hanky-panky and equal ownership to everything, however, their equality between all humans, of any colour or sex, predates even the American Declaration of Human Rights. Going by the growth and success of the Shakers, its clear that their social structure had something good about it. Abolishing social hierarchy and sharing out equal responsibility gave everyone a purpose. The community was one and had to work as one for it to succeed.

In respect to Shaker style, the principles are also ruled by strict guidelines, all in the nature of worship with no profane distractions. Generally there was three colours, blue, green and white. Buildings of particular purpose could only be painted in the corresponding colour. The sexes were separated so buildings were split, however, both sides were exactly the same, equal. This lends itself to their balanced proportions.

The furniture was their big money spinner. Personally, all I see is World War II Utility furniture (I get into this later on) The designs are scaled back and the craftsmanship is the aesthetic. The Shakers worked on a form-follows-function idealism decades before the word Modernism was first strung together. They strived for perfection and purity in everything, and their built environment was how they manifested this. Design played a key role in ritual, daily worship, everyday functionality as well as identity. I'm looking forward to understanding more examples of their furniture and manufacture.

To completely separate themselves from the rest of the 'profane world' and create their own utopia may seem strange, it may seem idyllic, either way the people chose to be there, and could chose to leave, surrounded by all the unrest in America at the time, and despite their strict way of life, the Shaker way of life was a utopian World to thousands of people for hundreds of years. Communities still exist today.

Now, I'm no historian, and I haven't finished the book, but regardless, the Shakers have grabbed my attention. I must say, I'm not thinking about becoming "Pip, the word" and some of the extreme laws are a definitely off-putting, however the social frame of mind at the foundations of the Shaker movement is an interesting model for study.

Thinking about humanities techniques of survival in the face of social adversity, I can relate it to the momentous example of the British Home Front during World War II. It is human nature to group together and close inward as a form of protection. However, the scale and speed of organisation of the Home Front is an incredible achievement. Within months 90% of the country was ready for agriculture. Quantities of propaganda were designed and issued to instruct, educate and ease the public. Local community schemes were set up; street food scraps for chicken and pigs, gardens dug up for food, neighbourly spirit that is like a dream to us these days. It must be said that this community-working-together-ness was enforced by government law, however it was for a clear and obvious cause. We refer back to the community spirit and Nationalism with pride. Nowadays we have broken communities; pockets of individuals that have no purpose or hope, they exist, that is all. With no focus or channel for constructive expression is it any wonder that a whole generation fired up and run riot on the streets that serve only the corporate establishments built on commercialism and globalisation?

A year ago I was reading up about British furniture designer and manufacturer Gordan Russell and his crusade for good design during the early twentieth century. He followed the values of the Arts and Crafts movement, but being a bit of a realist thought it was a bit silly turning your backs on all machines completely. He was designing during the height of political, social and industrial higgidy-piggidy, but with the combination of design integrity (not ripping off previous design, designing to function and production) and responsible manufacture (giving your staff some decent air to breath, and high quality but keeping costs down for accessible purchasing) he had double the incentive to get out there and lecture the public about what they should demand from a cheating industry. And good on him!

And that is where Gordan Russell is my man. He was part of a group of designers and thinkers that recognised the social and industrial malpractice and preached against it. Before the World Wars it was an ongoing fight for change (although, they were trying to sell plain, boring Modernism to a Georgian-loving market) The irony is, the World Wars meant that politics stepped in and removed all other design choice away, replaced it with the Utility furniture scheme (Gordan was on the Board of Trade committee, where he enforced the Modernist ideals under the guise of Utility) the public hated it because it was plain and boring, but then after the war, Modernism was dynamite. 1951, the Festival of Britian and Gordan Russell was on fire! President of the Design Council he continued his crusade for good design through education and industrial promotion. The design industry in Britain has flourished ever since.

Hundred years on and I can't help but feel we've gone full circle. We are faced with mass-produced everything, value is lost, waste increases and resources deplete in the background. Time ticks away and while more recognition pops up in media, on the streets ignorance is bliss when it means you can watch your uber cool 64" plasma screen. Profits take priority over the bigger picture. Individuals exploit the masses, the masses are ambivalent, et cetra et cetra. It makes my head spin, thats why I like to read about people like Gordan Russell and Ann Lee that saw a way forward and did it for themselves. It rung true for the people around them, Gordan Russell in Government, Ann Lee with her equality-loving followers.

The big thing that seems to treacle away time and time again is VALUE. To value someone or something is to care and appreciate. To understand its qualities and treat it with respect.

Were design played a vital role in identity and spiritual ritual for the Shakers, and survival and education for the Home Front, design since the late 20thC to now seems to have played its own part in the difficulties we face today. With mass production, products have become cheaper, and the throw away culture began, the life span of a product was shortened and now people go shopping with the 'temporary solution' attitude. In reaction to this the manufacturers have to bring out the next, new product, far more impressive and necessary! than the last. Slowly over time, the market is becoming dominated by a only a handful of shops, and even those are competing over designs of the same function and slightly varying appearance. In a global industry the market is saturated and commercial and materialistic success is the be-all.

For the craft industry, competing with the speed and price of mass production has become almost suicidal. The scary thing for me is to think that the world has forgotten what value a piece of art or furniture or pottery deserves. Has it forgotten that a high price doesn't have to equal a label of kudos, but instead a standard for craftsmanship, honesty in material, individualism and everlasting? Does it appreciate that something bespoke and handmade is created at the rate of the makers skills and experience? Is the desire to have 'slow-products' still there in peoples psyche, or will they never wake up from the convenience, and damaging, mass-produced dream?

And for me, design is the desire, cause, solution and hope for whatever has gone and whatever happens next.

Tea Time Tray

Over the past couple of weeks we've been busy blitzing through the workshop, cleaning and clearing out a few things. Its all in aid for the Open Studios event starting 17th September until 2nd October. Organised by the wonderful people at Eden Arts, over 100 Cumbrian artists and craftspeople will be throwing open their studio doors to the public and giving demonstrations of their unique skills. Everyone at DF Timber have taken it as an opportunity to publicly mark the hand over from Danny Frost to Huw Lowden and Steve Younger, the company's long standing employees. Its an exciting time for them, I wish them all the luck in the world.

Check out the website and keep an eye out for the bright yellow signs: www.c-art.org.uk

So, it was during this clear up that I stumbled on these old kitchen cupboard doors, and seeing as the new office needed an all-important tea-time work station I decided I'd turn them into a tray.

Kitchen door material

I decided I'd try some new techniques so I designed it with a wooden frame with curved corners.

Using off-cuts of Elm, I machined them up to strips of 40 x 40. The wobble saw on the spindle moulder was perfect for cutting out the L-shaped profile of the framework.

Wobble saw for frame

The corners were the really tricky bit. Luckily I had a beastly drill bit that was just the right diameter for the curved look I wanted. However, I had to be careful with the grain direction so as to not cause any weak points when its all glued together.

Once the drill (and pillar drill) had finally munched its way to just the right depth (it didn't half get hot and smoky) the corners with the perpendicular grain were cut out and squared off.

With a basic jig for the dowel joints, holes were tentatively drilled into the end grain of each piece.

The band saw cut out the curve, and all that was left was to spoke shave them to shape. It was so satisfying, I can tell you! The colour change from the frame sides to the end-grain corners really comes out now its oiled and after a quick sand with 240, its nice and smooth.

The kitchen cupboard doors are made of dodgy chipboard so the edges were sealed with a little PVA. Just gotta wait for the glue and oil to dry before sealing it all together...

2Hour Stool redefined

The first 2hour Stool design didn't quite hit the mark, so I smashed out a new prototype which had a few dimensions changed, joints revised and techniques practiced. Spoke-shaving the bevel by hand may mean I have a 4hour stool (at least), oh well, I'm so chuffed with how its turned out. The biggest difference has been the stunning off-cuts found in the machine room. A pretty rare 15" wide Wych Elm board sat smiling at me, and it's different grain direction has really added something special to it. Coupled up with the bit of Ash found in the same pile, for the legs, its the prettiest prototype I've ever made. While machining the Ash, its grain got more and more beautiful, and then cutting it to shape and planing, the ripples just shine. A poor mans Sycamore, lovely.

I've also included a few oiling pics, purely because I always get a kick from the deep, rich change of colour and reflection in the wood on the first coat. The camera really doesn't do it any justice.

Next is to make up some time saving jigs, set up some batch manufacturing and practice the hand skills, then, ta-dah, pips stool.

Stool no.1
Happy oiling Elm
Second Prototype

Challenge: 2hour Stool

The workshop has a challenge; to create a economical stool that's quick to make, practical and, of course, good looking. The record, from machining to finished product, goes to Huw's elegant plinth stool, created in 2.5 hours.

So today I set off at 8.30am, armed with one drawing and oodles of positivity that I could come close to competing with the Champion. As the day closed in at 6pm, I had to tip my hat in defeat. Although, it was only prototype day...

Elm legs
Mark up / square off
Cross rail detail
Stool gluing up

Stages of Handmade

This blog is the daily diary of my current projects, with a few inspirational finds sprinkled inbetween.

From timber selection, machining, all the way to a finished and oiled one-off piece. So stop by and check what I have been up to. It'll be exciting to see each piece develop and come together.

Arts & Crafts Bookcase
Ben's bedside table

A few of the construction and gluing stages

thank you holly

Here I am, all blogged up and ready to roll. I'd like to send out a huge thank you to Holly Falconer who graciously gave a lonely little bike a good home in exchange for setting up this blog and my website.

Check out her stuff, its a guaranteed good gander.

Muchas gracias se