Monthly Archives: May 2014

As I was thinking about the handle for the “Thorsen cabinet” last night I decided to update my CAD model to include it.  That always helps me think through what to do.  The price to buy this is more than I want to spend, although I’m not quibbling about it being expensive pre-se.  I know that this takes someone time to make in small batches.  I think I could probably make one on my lathe in a couple of hours, although it’s pretty fiddly work.  The handle itself would be two small tapered shafts, one with a ball turned on the end.  The ball would need to be counterbored for the second tapered shaft.  Then the parts could be silver soldered together.  Or, plan “B”, I could fabricate it in wax and take it to a local art foundry to have it cast in bronze via the lost wax process.  I’d have to check on the cost for doing that, it might be prohibitive.

For anyone who is curious, this is more or less how I got into designing and manufacturing chopper parts years ago.  I don’t know that I want to get into the cabinet handle business…

Handle Closeup

I made a few other updates, I added the shelf pin holes and a shelf with a sculpted edge, and started working out how to do the lead reveal around the edge of the glass.  I found a few small errors in the model and corrected them too.  Once I get all of the carcass assembled I’ll update the plans with the details on the door construction and publish an update.  For today, it’s about time in the shop.

Cabinet with door removed to show shelf

I really like this design, and “props” to Dale Barnard for the design adaptation from the original (larger) Thorsen house cabinet.  I thought it would be good to take a look at the original, so I bought the Makinson book that was supposed to have a picture of the original cabinet (I was surprised there was a G&G book I didn’t have!).  Sure enough, page 142.  The cabinet I’m building is pretty obviously a direct derivative of this, using the layout of the left door but with square proportions.  Looking at the original cabinet I’m stunned at how well the shapes and proportions work together, and how well it’s integrated into the room.  Check out the built-in supports, and how the trim on the wall follows the shape of the supports and the cabinet top.  OK, wow.

It’s worth noting that the original cabinet doesn’t have a pull, but instead has what appear to be carved escutcheons as are seen on other G&G cabinets.  They generally made carved ebony handles for the keys that opened the locks.  This might be another approach to the “knob situation”.

Original Thorsen Cabinet

Finally, here is an overall rendering of the cabinet I’m building.  I need to add hinges and the stained glass “clouds” to the model still, but it’s mostly done (in CAD) other than that.  I’m heading out to the shop to get the wood version caught up to the digital version shortly…

Latest CAD model of the cabinet

It doesn’t look like much, but I got a decent start on the Thorsen Cabinet yesterday.

I spent a couple of hours tweaking the CAD model — spread out over the day — as I found errors or missing information.  I also started developing printed plans that I could take to the shop as a reference.  The CAD model doesn’t look substantially different, but I made several small adjustments to the details.

This is the first version of the plans that I’ve posted — there will be more as I build this project.  At the very least I’ll need to draw up the door for the cabinet and patterns for the stained glass.  As I build it I’m sure I’ll discover errors or construction details I want to add in.

Updated Rendering

My main goal for the day was to rough mill all the lumber for the case.  I accomplished that, although I forgot about the back somehow.  I wanted to get the wood flat and square, then give it time to “acclimate” — which I’m convinced really translates into “warp”.  Today I’ll see if it moved and get it machined to final dimensions, cut the rabbets and dados and get the carcass mocked up.  We’ll see how far I get, I also have a project I want to do with my son, and that takes precedence.

The Sapele seems to machine without any particular tendency to tear out, I’m eager to see how it reacts to final finishing with a hand plane.  I’m already wondering how I’ll finish this.  The color is brownish-pink, and it darkens over time to a reddish-brown — although with finish on it that will take years I expect.  I think I’ll probably want to use a little dye to get to the color I want, then topcoat with oil and shellac.  I’ll need to do some sample panels later.  It has more color already than most of the Honduras Mahogany I’ve worked with.

Wood for the cabinet case. The two leftmost oars are the sides.

Stickered and acclimating. The 8/4 board is for the aprons.

OK, things are looking up.  My wife insisted that I make the drive to “the wood store” yesterday afternoon even though I didn’t have a plan for what I wanted to make.  Traffic was hellacious, we live near Santa Cruz, which is a popular vacation spot and throughway for weekenders heading down the coast to San Louis Obispo or Pismo beach.  So it was a long hour-plus sitting in traffic, which gave me some time to think through what to start on in the shop.  And to resist getting frustrated with traffic and turning around.

In the end I decided to make the Thorsen house inspired cabinet.  I’ve wanted to make this project since I saw it offered as a class at the William Ng school, and when the Popular Woodworking video came out a few weeks ago I snarfed it up.

I went to Jackel Enterprises in Watsonville to get the wood, and they had just gotten in a ton of Sapele, which is what I decided to use.  Normally I’d use Hondouras Mahogany, but I’ve been wanting to try Sapele.  I got about 24bf of 4/4 and one stick of 8/4.  It should be enough, certainly enough to keep me busy this weekend.  The widest board is over 12″, that had a few that were even wider.  At six bucks and change a board foot, plus an arm and a leg for the governor I got out for about $230.

About 32 board feel of 4/4 and 8/4 Sapele for the cabinet

On the subject of the video, I have mixed feelings.  I was really annoyed that the “plans” didn’t come with the downloaded video — they are supposed to, but there was some problem and they weren’t there.  It took a week of emailing and calling their support folks before I got the drawings.  The finished project looks absolutely great, the video and plans have some thin spots.  It really bugs me that they use drywall screws to put the case together, that just seems like schlock to me.  I don’t like using plywood on the back, and the fact that they patched the back together from two pieces shows they were just slamming this together for the video shoot.  I did pick up a couple of tricks for building the cabinet,  so I’d give the video a C or C-minus.  The dimensions in the plans have several errors too.

So I figured I’d better make a plan for how I’m going to make this.  I started with the “plans” that came with the video, and started modeling it in CAD.  It didn’t take long to get the case all modeled, and I found several errors in the drawings and cut list.  Instead of a 1/4″ plywood back I’m going to use 1/2″ thick ship-lapped slats.  I’m skipping the “screw rails” in the drawings (which are just flat strips glued inside of the cabinet to the plywood back to drive screws through into the wall).  Instead I’ll recess some keyhole hangers on the back, I want to use the Sanderson Hardware Hangers this time instead of the hardware store variety because the have offset screws so I can be sure the drive through the back slats into the side of the case.

I need to run down to town to pick up some screws and paper for the printer so I can take the dimensions out to the shop with me, then I’ll be ready to start milling wood.

Thorsen house cabinet case design