My client was in the lumber business and wanted a solid tiger maple mantel for the company office. The first order of business was to find a log suitable enough to cut a 6x8x96 inch blank out of. The company was about to have a log auction so I had quite a selection of logs to pick from. I had the log cut at a local sawmill the main section weighed about 400 lbs. Next came the problem of drying the piece. After consulting with the kiln operator we decided to drill out the back with a series of 70 two inch by 4-inch deep holes to relieve the drying stress and minimize the checking. It took 5 weeks of manhandling and nursing it in and out of the kiln to get it down to 8 percent, it came out almost perfect. Once I had it back at the shop the client decided the grain would be enhanced if the center were dished out. I had my fingers crossed the router wouldn’t hit one of the 70 holes and ruin the whole affair.
The mantel was finished with several coats of Watco Natural Oil, let dry for 5 days, and washed down with lacquer thinner to remove any surface film and top coated with 3 coats catalyzed lacquer.
The mantel was fastened from the back with steel hangers tapconed to the masonry. The pillars were screwed through the four peg holes, pegs are square walnut plugs. Incidentally the entire mantel including pilliars and trim was cut from the same log.
Replies
Detail Shot
Photo of concave router jig
Armin,
Very impressive piece of work. I like the concave detail, and that jig you had was pretty neat too. I like on the second picture how the figure shows. Keep up the good work.
Mitch
Armin , I like that mantel . I did a scoop out kind of like thatfor a concrete form , only I cheeted I took the bearing off of a radius panel raising bit and then ground off the bearing boss. Worked great and worked the router greatly.
Armin,
I'm curious about the attachment. You said it was screwed in from the back... this means you got into the fireplace, drilled holes all the way through, and put your screws into the mantel from there? Woah.
Tom
Tom D. No I didn't get inside the fireplace. I fabricated two steel brackets sort of on the order of heavy duty bed rail fastners and tapconed them to the masonary. The back of the mantel had two steel plates routed in on a taper to mate with the hangers. I shimed the plates till I had a tight fit then gave it a good last rap with a hammer and snugged everything tight to the wall.
Nice solution!
I'm also working on a mantel, although not nearly as massive as the tiger maple one. It's a curved shelf essentially, about 1 1/2" thick, that comes out of a rough limestone block wall. 2 small laminated curved supports come down from below the shelf to keep it from flopping down, but I've wondered about the best way to actually attach it to the wall. I now think that a couple of keyhole shaped plates in the back could do the trick.
Thanks for posting your work and taking the time to reply to my question.
Tom
Hey looks nice.
What about just running the cove on a table saw with the fence set at an angle. raise a little at a time and there you go.
Hey Armin; Very nice mantel! I am sorry it took me so long to find it.
Pray tell, how did you drill 70 2' hole 4 inches deep in maple? Forstner bit? I can not imagine the work. You are a talented craftsman.
I'm drying a piece of cedar as we speak and hope to have it done in a year or two. The client is waiting for a twelve by eight by 96! Another year or two I keep telling Him. I'm going to look at your method. But first, where is that sled project for the drill press?
I admire your work and enjoy your posts. Thanks!
dadaka Old and late Pro
does anyone know where I could find some tiger maple rough lumber?
Just go to any sawmill that cuts maple. they will have tiger maple separate from the other plain figured
A lot depends on where you live, it might be kind of tough to find a sawmill in Texas that saws maple. Where are you located, maybe I can help you find some.
I am in Richmond, Virginia.
Jeeze, I was just there could have brought you some.
Try Groff lumber in Pa. 800 342 0001
You are in a good general area for curly maple so Stan's advise of checking with smaller sawmills would be a good start, I suspect drying it will be a bigger problem than find a piece, how big a plank are you looking for?