To date, all of my woodworking projects were for me, by me.
The Hidden Lock Cabinets my son and I are making for him has become an interesting collaborative effort. He throws out ideas and I give him options on how to do it or why it would be tough to do. Last nite we had a Bumble Bee Syndrome event.
Explanation: With what we knew at the time - prior to high speed cameras - bumble bees weren't supposed to be able to fly according to the theories we had on aerodynamics. The bumble bee, not knowing that he theoretically couldn't fly, flew. History is full of folks who were told "It can't be done!" and they went and did it anyway. When I was teaching lost wax casting I'd get a student every now and then who, out of "ignorance", did something that every thing I knew from personal experience and from books, classes etc., couldn't be done. Sometimes it could be repeated and sometimes it couldn't. If it could be repeated it went into my class handouts for others to use if they chose to.
In this instance my son wanted to make the top out of birdseye maple. He rejected using birdseye ply because he didn't want to frame the top to hide the edges of the ply. That left making the top out of edge joined boards and breadboard ends would likely be necessary. He dug out 6 birdseye boards, a smidge over 3/4' thick by 4-5 inches wide by 47 1/2" long. He layed them out on the bench top and he played the board shuffle and switch and rotate game for about a half an hour.
Only when he had an acceptable to him set of boards that would yield what was needed did he notice that the birdseye figure wouldn't be on the exposed edges of the top.
He wanted the birdseye figure to be on the edges of the top as well. "Don't they make the stuff they cover the ends of ply with in birdseye maple?" Had to tell him I'd never seen or read or heard of any. Told him we could frame the top panel, but in solid wood we'd probably need breadboard ends because of acrossed the grain expansion and contraction.
"Does ply move like solid wood?"
"Nope."
"Then what if we did the top out of birdseye ply and frame it with some of the solid wood birdseye?" He they sketched up what is a rabbet for the ply to sit in and a chamfered edge to desguise the transition from horizontal to vertical - keeping as little non-figured wood visible. Here's what he came up with.
++--------- / | Birdesye ply | | | +---+----- | | Solid birdseye with figure on +----- + the outer faceWith mitered corners, possibly with a contrasting wood feather, it might look like what he wants - grain flowing off the top onto the edges and down onto the front panel which will also be birdseye. (This kid has expensive taste).
Put the birdseye maple boards away and got out a sheet of birdseye ply. Stuck two framing squares together to create a window the size of the top and turned him loose to find the areas of the sheet he wanted to use. As is often the case with figured ply, there were stains and dead spots in critical locations. The board shuffle was trivial relative to finding what he needs in ply. He'd find what he wanted for one top but that'd not leave any he liked for the second top. This is like putting together a music set! Getting everything to flow together is hard - but fun!
An hour later we marked what he wants with Post It dots at the corners and called it a night.
I'll rip a piece of the solid birdseye, route the rabbet/rebate and chamfer the top edge so he can see a sample of his idea in the actual stuff we can use.
The evolution of his design has brought up an interesting design issue. The grain on the top of the cabinet well flow acrossed the top from left to right. The front panel however would, if made of solid wood, have to flow up and down. Having the grain flow left/right on the front panel seemed "wrong" to me because of my bias towards solid wood furniture.
"But dad, with the birdseye, the grain direction isn't going to be noticable and we're going to use ply!"
I got caught up with The Rules and overlooked the specific materials and application. It's the Exception To The Rules that you have to be open to. And it doesn't hurt to work with a "bumble bee" either.
This is turning out to be even more fun than I'd hoped for.
charlie b