Christian Dunbar: Walnut Flame Process

Using various modeling tools and scale to design a piece at the specific dims for the space that I was hoping to fill.

Registration rods: Pink from upper plate, green from lower plate.

Using "contour" command to produce cut lines 8/10" apart, to be mapped onto walnut boards (shown in magenta) for laser cutting on BEAM cutter.

Placing first walnut board into BEAM cutter.

BIG Beam laser cutting.

Lower registration plate, parts 1 - 10.

Continued glue up, day two.

Walnut dowels as registration rods.

Glue up, day 4.

Negotiating registration rods from upper plate.

Glue up day 5: top cap piece!

Interesting study of vertical rods defining a curved plane within an undulating 3 dimensional space.

Beginning to sculpt.

Moving through walnut like butter!

Smoothed transitions...kinda.

Beginning of sanding.

Smoother...

Close-up view of registration rods.

Crotch needing to be sculpted out. This would be tricky.

Top cap piece, showing wood grain.

Smooth, pretty good curve lines. People thought it looked like MDF at this point...not good. Continued sanding up to 2000 grit.

Figuring out cantilevered placement on steel plate.

Pre-drilling for bolts from underneath.

Application of secret finish.

Two coats of finish. Looks liquid... woo hooo!