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Federal Inspired Huntboard

author-gravatar nicholas.vanaria Aug 09, 2018

Federal inspired huntboard.  Made from Sapele Mahogany with inlays.  Currently in progress and posting photos as I go along.  I will update the project cover photo when it is complete.

Photo of Federal Inspired Huntboard

I don't do full size or complete drawings when I start a project.  I normally just sketch out a part of it, and then build it on the fly as I go.  This is the preliminary start that I will go from. 

Photo of Federal Inspired Huntboard

Laying out the way I want the leg inlays and stringing to look.

Photo of Federal Inspired Huntboard

I am fortunate enough to work at a hardwood supplier, so I was able to pick up these three pieces of flat sawn Sapele for under $80.

Photo of Federal Inspired Huntboard

Splitting the parts to glue up the legs.  I'm trying to find the best grain match so the seam will be invisible when glued up.

Photo of Federal Inspired Huntboard

One down, three to go.

Photo of Federal Inspired Huntboard

Good thing I have over 125 clamps on the shop.  BUT, you can never have enough!!!!

Photo of Federal Inspired Huntboard

Using my leg template to mark for the tapering of the legs.  The legs will start their taper just below the "bullet" inlay I am going to be making.

Photo of Federal Inspired Huntboard

Layout Marks.

Photo of Federal Inspired Huntboard

The Pica marker with the white marking insert is invaluable when marking dark woods.

Photo of Federal Inspired Huntboard

Cutting out the tapers.  I leave them just a tad heavy to clean them up on the jointer.

Photo of Federal Inspired Huntboard

That Laguna bandsaw is one of the best investments I've made.

Photo of Federal Inspired Huntboard

Laying out the legs so I can keep the tapers straight.  I always put the best ones in front.

Photo of Federal Inspired Huntboard

After bandsawing them out, I clean up the marks with one pass on the jointer.  It leaves a nice, clean surface.

Photo of Federal Inspired Huntboard

All tapered out.

Photo of Federal Inspired Huntboard

Let the inlay begin!!!!  I use an auxiliary bench clamped to my regular bench.  I am 6'4" tall, so the higher bench makes all the up close work I have to do with chisels, router planes, etc., much easier (and more accurate).

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Heating up the sand to sand shade the Newport Book inlay and bullet moulding to compliment it.  The tongs are hand made from a local blacksmith.  I love them, and they keep my hands away from that hot sand.

Photo of Federal Inspired Huntboard

Using a wider piece to shade, and the ripping the strips out of it, make it easier to handle.

Photo of Federal Inspired Huntboard

The 4 sections of the "book".

Photo of Federal Inspired Huntboard

Taped up and ready to cut out the top and bottom.  The lines on the inlay help me to register the chisel properly so the final product is consistent.

Photo of Federal Inspired Huntboard

I use the same chisel to cut the top arches and bottom coves of the inlay.  Slow and steady.

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All cut out with the chisels.

Photo of Federal Inspired Huntboard

Using the same chisel, I mark out the area on the legs to excavate for the inlay.

Photo of Federal Inspired Huntboard

The Dremel helps to hog out most of the material for the inlay.

Photo of Federal Inspired Huntboard

Good old fashioned router planes help clean up the rest and get into the tight areas.  The little one, with the pointed blade is a Godsend on an inlay like this.

Photo of Federal Inspired Huntboard

Using Old Brown Glue to inlay the Book into the freshly excavated cavity.

Photo of Federal Inspired Huntboard

I made a Maple and Wenge 2 piece banding for running around the Tiger Maple square inlay that will be inlaid in the leg beneath the Book.

Photo of Federal Inspired Huntboard

More excavation.

Photo of Federal Inspired Huntboard

Squaring up the corners.

Photo of Federal Inspired Huntboard

Tiger Maple for the square inlay.

Photo of Federal Inspired Huntboard

Resawing the square inlay.

Photo of Federal Inspired Huntboard

Square inlay inlaid in leg.

Photo of Federal Inspired Huntboard

Starting to inlay the Maple/Wenge stringing around the square inlay.

Photo of Federal Inspired Huntboard

I absolutely love my Bessey DuoKlamps.  Just a shot of them holding the leg in place as I work on the border of the square inlay.

Photo of Federal Inspired Huntboard

Using the kumiko block I got from Mike Pekovich to miter the border.  Perfect miters.

Photo of Federal Inspired Huntboard

Progress of square inlay border.

Photo of Federal Inspired Huntboard

Done with the square inlay border.

Photo of Federal Inspired Huntboard

Close up shot of the square inlay border.

Photo of Federal Inspired Huntboard

Lie-Nielsen stringing cutter based on the Steve Latta design.

Photo of Federal Inspired Huntboard

The cutter rides along the edge of the leg and follows the taper perfectly.

Photo of Federal Inspired Huntboard

The grooves take under 5 minutes to cut and they are perfect with this cutter.

Photo of Federal Inspired Huntboard

Using the radius cutter to cut the arc for the stringing and my Walke Moore protector pad place the point.

Photo of Federal Inspired Huntboard

Finished the arc.

Photo of Federal Inspired Huntboard

The stringing for the legs.

Photo of Federal Inspired Huntboard

Planing the maple down to begin making the "bullet" banding.

Photo of Federal Inspired Huntboard

The "bullets" made with one concave side and one convex side.

Photo of Federal Inspired Huntboard

Slicing them into small pieces.

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All of the cutting for the "bullet" pieces.

Photo of Federal Inspired Huntboard

I used Whiteside bits to cut the concave and convex sides of the banding.

Photo of Federal Inspired Huntboard

Using the same setup I had for the Newport Book to shade the "bullet" pieces.

Photo of Federal Inspired Huntboard

All of the pieces with sand shaded fronts.

Photo of Federal Inspired Huntboard

Line up the the pieces to get the length.

Photo of Federal Inspired Huntboard

I will band the outside of the pieces to give it a nice border and help hold the packet together.

Photo of Federal Inspired Huntboard

My banding jig that I use to glue up the pieces.

Photo of Federal Inspired Huntboard

My shop helper helping me apply glue.

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This is what the banding looks like after applying a double layer of Maple/Wenge.

Photo of Federal Inspired Huntboard

I sliced the packets to get 11 strips of banding that will go along the bottom rail, wrap around the legs, and travel down the sides.

Photo of Federal Inspired Huntboard

I mark for the excavation of the banding.

Photo of Federal Inspired Huntboard

Chisels and router planes work best for getting smooth, controllable results.

Photo of Federal Inspired Huntboard

Perfect fit.

Photo of Federal Inspired Huntboard

As I wrap it around, I try to have the banding "chase" itself so it looks like it is flowing around instead of having it uneven on one or more sides.  One continuous band.

Photo of Federal Inspired Huntboard

This is a Maple/Wenge/Maple banding I made for the cuff at the bottom of the leg.

Photo of Federal Inspired Huntboard

The cuffs are installed using the same methods as installing the banding around the legs.

Photo of Federal Inspired Huntboard

Finished shot of the legs.

Photo of Federal Inspired Huntboard

These will be the front of the crossrails.

Photo of Federal Inspired Huntboard

These are the backs.  I am not going to be cleaning them up.  More often than not, the non-show faces of fine period furniture was never cleaned up or dressed.  I am going to leave mine in the rough as a nod to the 18th and 19th century furniture maker that came before me that I am trying to emulate.

Photo of Federal Inspired Huntboard

My shop is about 750 square feet.  I am very fortunate.  BUT, it is set up around the post jacks to be able to easily handle and rip 4x8 sheets of material.  I bought some 5x5 Baltic Birch and couldn't break it down in the shop, and my track saw has a 55" rail, so I had to bust out the jigsaw to rough cut it to a manageable size.  Next time I'll buy the 4x8 Baltic Birch.

Photo of Federal Inspired Huntboard

Waterfall Bubinga that will be used for the door panels and drawer heads.

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Pressing the Waterfall Bubinga onto 1/4" Baltic Birch plywood for the door panels.

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Pressing the Waterfall Bubinga onto the 3/4" Baltic Birch plywood for the drawer heads.  You can never have too many clamps, that's for sure.

Photo of Federal Inspired Huntboard

Sapele Mahogany stile and rail parts cut to make the panels on the side.

Photo of Federal Inspired Huntboard

My trusty DeWalt dado set.  This set has served me well for many years.

Photo of Federal Inspired Huntboard

Holding the stiles and rails tight to the fence to get a perfectly centered groove for the panels.

Photo of Federal Inspired Huntboard

Grooves...Centered.

Photo of Federal Inspired Huntboard

Testing to see how it'll look and to take final measurements for the panels.

Photo of Federal Inspired Huntboard

I don't use my Bowclamps often, but when I need them, they are invaluable.  These will put even pressure in the center of the clamp-up while pressing the Waterfall Bubuinga veneer to the the substrate.

Photo of Federal Inspired Huntboard

Bookmatched Waterfall Bubinga for the side panels.

Photo of Federal Inspired Huntboard

My newly completed set of Lie-Nielsen chisels.  Got the last 3 for my birthday (happy dance).  :-)

Photo of Federal Inspired Huntboard

Using my Festool Domino to join the stiles and rails. 

Photo of Federal Inspired Huntboard

Perfectly square!!!!

Photo of Federal Inspired Huntboard

I purchased this angled pliers many many years ago for another purpose, however, I have found it to be the absolute best for pulling out Dominos that are in their mortises.  It gives great leverage and doesn't mar the surface.

Photo of Federal Inspired Huntboard

Using my Woodpecker's square to score the lines where I will be cutting the panel to final dimension and making sure that the bookmatched center is centered in the panel.  By  scoring the line before I cut, I am insuring that it won't fray from my tablesaw blade.

Photo of Federal Inspired Huntboard

Panel assembled.

Photo of Federal Inspired Huntboard

I ran a small rabbet along the bottom edge of the side panels and inlaid the "bullet" moulding I made.  This will continue on around the legs.

Photo of Federal Inspired Huntboard

One side assembled.  This will be the left side of the huntboard.  The right is a mirror image.  Notice how the "bullet" banding travels around the front leg, along the panel, and to the back leg.  This is repeated on the right side.  However, there will be a transition point along the front of the bottom crossrail as the "bullets" travel in opposite directions (by design).

2 comments

Wow, looking forward to this one! What base is that on the dremmel?

Thanks Sean!!!! Me too.  LOL.  That is the Veritas base kit.  It is incredible for doing this type of work.  Highly recommended!!!!

@Sean  said:

Wow, looking forward to this one! What base is that on the dremmel?

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