Sam Maloof

I have been pretty bummed out the last couple weeks after learning of Sam Maloof's passing.  At 93 years old, we was the hero and role model for woodworkers and craftsmen worldwide. If you don't know much about him, his story is fascinating. You can read more about his life here. I became familiar with Maloof's work years ago, and immediately loved his beautiful designs and personal philosophy. For years I've wanted to build a rocking chair based on his design, and I think it may finally be time to do it. I've always thought that if I had to invite 5 famous people to dinner, he would be one of them. He was brilliant.

The End of Katrina for Me

I’ve spent the last few weeks completing the restoration of a very old armoire. This was the last Katrina flooded piece for me, so it had extra meaning beyond the usual project. When I went to evaluate the armoire some time ago, I wasn’t even sure what I was looking at. It had been piled in a carport for 3 years. Many of the joints had failed and there were pieces everywhere. It also had that all-too-familiar lifeless look with stains and grime that is typical of furniture that spent some time in the watery sludge that overtook much of New Orleans. When the client accepted my estimate, I was surprised. A piece of furniture that is that far gone must be something special to embrace the possibility that it can return to its former glory. Of course, there were no photos of the armoire to reference, just the parts that remained.

It’s always an interesting prospect starting a project like this. In many ways, it’s hard to know where to start and even harder to get motivated to start after spending so much time with flooded furniture. The only parts that were intact were the doors, so that is where I started. The process of cleaning, stripping, bleaching, sanding, straightening, and conditioning the wood is a long, arduous endeavor. This armoire had a lot of parts, and all of them got the treatment. While I suppose it would have been easier if would have ignored some of the hidden areas, it didn’t seem right to do that. If I had to put my clothes in there, I’d want to know every last bit of Katrina was gone. Most of the armoire was nailed together, and the old iron cut nails left an array of stains. Most of the nails were so brittle and rusted that they broke off in the wood in both directions. I don’t know how many hours I spent just removing all those nails, but it was a lot.

After weeks of getting the bulk of the preparations done, it was time to figure out the jigsaw puzzle and make this into an armoire once again. Murphy’s Law was at work throughout this project. Every time I thought I’d treated each part, another turned up. I had to recreate many missing parts as well, and each time I thought I had all the pieces there was always one more to make. This carried through right until the end. When we delivered the piece last Saturday, I realized I brought everything but the skeleton keys for the doors. The armoire had one last laugh at my expense, but I’d like to think I won the battle. It all went together again and it was hard to believe this was the pile of parts I’d seen months earlier in that carport. When we got it fully assembled, the customer only said one word: “WOW”. That was all I needed to hear.

Cleaning Up Messes

It's been crazy busy the last couple weeks in the shop. I completed work on eight dining chairs and delivered them yesterday. I have never seen such a pathetic finishing job as what was on these chairs. The amount of dust, drips, runs, and poor application were inexcusable in my opinion. I just can not believe any finisher with a conscience charged for this work! With a lot of wet sanding, some color correction, and a hand rubbed finish applied, the chairs felt silky smooth and looked beautiful. The customer was very pleased and I was happy to have that whole bunch done.

Although I normally do not refinish exterior doors, I made an exception for the same customer with the chairs mentioned above. Their front door was a full 11 feet tall! I spent most of last Saturday up on a ladder stripping, sanding, repairing, and staining the door. It took a few more trips over there this week to get the marine grade topcoats applied. I remembered why I do not do exterior doors. If I can not bring it to the shop and work on it in a reasonable way, it's quite difficult to work efficiently. The door did come out beautifully and I'll be quite content to not get back up on the ladder for awhile.

Aside from the usual time spent daily on the ongoing armoire restoration, I took in another 6 chairs for repair. I did not need more chairs - that put the total to 22 chairs here last week. These chairs won the prize for having the most glue dumped in every joint, yet every joint failed. At least no one had driven nails through everything like I usually encounter. They also had about 40 years of wax buildup on the finish. They looked and felt a lot different when completed. Getting the finish clean and the joints solid was long overdue. Some weeks it seems I'm just doomed to clean up one mess after another. At least the week rounded out with 5 normal web caning jobs. I also received a beautiful old rocking chair with a hand caned seat that is falling apart. I got so burnt out on rattan work early last month, but already miss it after a few weeks. It will be nice to do a normal seat - not round, oddly shaped, blind caned, wrapped, or anything else - just good old fashioned 7 step cane pattern.

Happy 2009

I’ve been getting a lot of requests to update my blog, and it’s obviously long overdue.  It’s been well over a year since my last update.  A good part of my time is devoted to working in the shop, but this past year brought a wonderful surprise – my son.  He is the best, and it is difficult to get motivated to work some mornings when it is such a joy to play with him.  Between all that comes with being a new father and running a continuously growing workshop, there is little time to write.

If you are a frequent visitor to the web site, you know that I update fairly often with pictures and descriptions of the latest projects. If it seems as though those updates have been happening less often, it is because I have had some projects that have lingered in the shop for some time. Today I finally finished a pair of rattan chairs I've had for some time. Clearly this is not the sort of routine cane or rush weaving I usually do, nor is it even a binder cane weave I've seen before. With the help of some other pros from the Wicker Woman's forum, books, and a good amount of head scratching, I finally succeeded. Usually when I get a seat apart, it's pretty obvious how it went together. This one was a mystery. I don't like to lose to a chair, though. I just hope I don't see another one of these for awhile!

My other two long term restorations are cabinets damaged from Katrina - the last two flooded items I have waiting. They are both major restorations: stained, broken, parts missing, etc. With any luck I'll have them both done in another few weeks. I'm so ready to be done with flood restorations that I've started turning them away. It is time to move on. I'm always a bit surprised when a new client contacts me about restoring flooded furniture after it has been sitting for three and a half years.

In addition to a slew of chair repairs, refinishing a Heywood Wakefield bed, restoring several yacht cabinet doors, and the normal caning work that trickles in, I also undertook the caning of some Cesca chairs from a client in Houston. It was a lot of caning as there were four seats with 100 holes each, and two backs blind caned with 86 holes each. I had quoted prices for the seats over the phone and was unaware that the chair backs were coming as well. After presenting the written estimate for the costs of both the seats and backs to the client, I was told to proceed. I ordered extra cane stock to be on the safe side, and I was glad I did. I went through about 2 weeks of problems with two of my suppliers. Apparently paying for overnight shipping means getting it a week later. Despite the supply delays and the rigors of blind caning, I completed everything and sent off the invoice. To my surprise, the client had a fit about the bill despite seeing everything in writing ahead of time. I'm still not entirely sure what happened, but I was glad I had a paper trail of communication to document my side of things. I think they just wanted to weasel out of paying the bill (as they admitted to considering buying 'fake' replacement seats and backs which are considerably cheaper). The long and short of it is that they agreed to satisfy the bill. I normally have such excellent customers who appreciate quality and are reliable. It always throws me off when I encounter one who is difficult. That is a fast way to insure we won't be doing business again.

This morning I picked up three more chairs. All of them are to be restored and recaned, and all of them are in pretty rough shape. These were new clients and they had a beautiful home. On top of that, they were super nice people. When I left, I had seven chairs in the truck. This happens a lot, it seems, but I don't mind. These were obviously people who value their furniture and are willing to have it treated right. Even though the temperature hadn't climbed out of the 40's when I was there, the woman carried chairs wearing her bathrobe... You've got to love the folks in New Orleans.

This afternoon's task is to finish up somebody else's dirty work. Last Saturday I spent a few hours rubbing out a table that had been refinished by someone else. It was a horrible finishing job. The surface was rough, dusty, and orange peeled. I don't know how any finisher with a conscience could let a table leave the shop looking like that. The eight chairs around the table were even worse. There are drips everywhere, uneven color, and the finish feels like a piece of old leather. I asked the client who did this so that I'm sure never to refer any work to them, and I'm still waiting to hear.

The Waterline

On Wednesdays and Saturdays, I get out of the workshop to do repair estimates. Most of the time this involves a good part of the day in the car going from one place to another taking pictures of furniture. I've been doing this for a long time and there isn't much in the way of surprises when it comes to doing the evaluations. What’s different about each estimate, however, is the owner. There’s always a story to go along with their furniture.

I’m used to hearing these stories and actually really enjoy them. Some people love to tell about the relative that built the piece, how long it’s been in the family, or simply what a great deal they got when they bought it. For the past couple of years there’s been an added chapter to those stories. It usually begins with, “When we got back after the storm (Katrina)…”

Everyone has their own story about the whole Katrina experience. It’s become part of every day existence in New Orleans; it’s unavoidable. I should clarify that: it’s unavoidable for those of us who live here. I suppose if you’re in town for a convention and never make it past the French Quarter and Warehouse District that you’d never give the storm a second thought. After over two years, though, there have only been a handful of days when it didn’t come up in any given conversation. People need to tell their story. I used to schedule my appointments a half hour apart, but now allow a full hour (at least). The first 5 minutes is the furniture evaluation and the rest is hearing the stories.

For the longest time, I thought I didn’t really have a story. We were lucky in that we only had a little roof damage to the house and three trees that crashed into my workshop. In comparison to what so many others went through, we were lucky. My story, as it’s turned out, is what has happened since then as a result of the work I do. Even though there is no storm damage evidence around my home or workshop, I’m entrenched in it almost every day. I keep thinking it will get easier, but it doesn’t. It just gets smellier. Just when I think maybe I (and those doing what I do) have gotten through all the flooded furniture that wasn’t thrown out, a whole new wave comes in. For some people, I know it’s just not a priority until all other repairs have been done. For others, they’re waiting for that insurance settlement. Regardless of the reasons, the end result is that I’m the one faced with the challenge of resurrecting their treasures. That is my story.

Last Saturday I went out to the Lakeview neighborhood. I’ve been in and around that area many times, but hadn’t been back to this particular street since a year ago January. I’m happy to report that there has been amazing progress there. A lot of people are rebuilding and others have had their homes demolished. Keep in mind that this area got anywhere from 6 to 9 feet of water depending on the block. The last time I did an estimate in a home on this street, the items were so damaged that it was difficult to tell what they were before the storm. I anticipated the same thing this time and I wasn’t too far off. The armoire I evaluated was a jigsaw puzzle of faded, dirty parts. It was clearly well made; few parts had warped significantly and it wasn’t covered with stains from rusted screws holding it together. Next to the armoire were a bunch of dining room chairs – also in pieces – that looked more like a pile of old driftwood. None of this particularly surprised me, though. It’s become part of the job. I suppose if I hadn’t just finished rebuilding and restoring another armoire over the past month, I would have had a different outlook on this one. But the thought of going through all of that again (already) was not nice.

When I was driving away, I decided to take the long way to my next estimate instead of hopping on the interstate. I weaved my way through neighborhood after neighborhood full of gutted, empty houses. Every now and then, there would be evidence of one determined soul who had returned. I saw one of them, and it struck me.

Now, if you haven’t been to New Orleans in the past couple of years, you probably wouldn’t even think about the waterline that decorates every building in an area that flooded. At this point a lot of them have been washed off or painted over, but not all. I didn’t realize for awhile how much it had become a habit to look for the waterline every time I was driving around town. There’s something about those waterlines that can gnaw at you and remind you of Katrina’s wrath. So getting rid of the waterline is a big step forward for many people. Sometimes, however, it isn’t that easy.

I was driving through mid-city New Orleans when I passed a house with a distinct waterline tattoo. There was a guy with a pressure washer out front. He had that nozzle going full blast on that waterline and he wasn’t winning. I watched as he moved the stream back and forth across that line trying to power it off. As he was doing that, he looked out at me when I was driving by. The look on his face was something I’ll never forget: beaten down, desperate, and exhausted. It was as if that waterline was the last thing in a series of battles he has fought. I bet he stayed there all day until he won.

Nails, Staples, Filler... Do-it-Yourself No-No's

It never ceases to amaze me how many ways people can find to "repair" their furniture. Every now and then I go through a period where it seems like all I'm doing is pulling out nails, prying out staples, or chipping away a dozen different kinds of glues on top of each other. The past few weeks have been like this. I've had an extraordinary amount of repair work involving broken chairs, beds, and tables. After so many years of seeing the same things, it's time to lay out a few ground rules for those who like to perform do-it-yourself repairs.

First, a word about nails. If there wasn't a nail there to begin with, don't put one there. Chances are the person who made the chair or table knew what they were doing and didn't plan on someone else driving a nail through the joint to make it better. Nails have a purpose, and it's not furniture repair under most circumstances.

More nails will not solve the problem, but more than likely damage the wood and create an unsightly mess.

I could say the same thing about staples. While it may seem smart to use a staple to keep a cracked joint together, it's a big no-no. Not only does it look bad, but over time it will pull apart. Often staples will split wood, too. Don't use staples. They're fine for holding in upholstery (sometimes), but otherwise they have no business in furniture repair.

Staples are a lazy repair that look bad and function poorly.

Glue is the woodworker's choice for keeping joints together, and different glues are used for different purposes. Some joints can be repaired using conventional carpenter's glue, but others should not. If you're not sure, don't slop a random glue in there and assume that it's going to hold correctly. One thing I encounter a lot is a joint where someone has dumped in an enormous amount of industrial epoxy. Yes, it holds. And holds. And holds. It makes disassembly a major chore for the restorer and can often result in damage to the piece. For many antiques, hide glue is the glue of choice for the restorer. It allows a long open assmebly time, holds strong, and is easily dissolved with little effort should the piece need repair later. If you do choose the appropriate glue, apply it correctly and wipe off any excess. Hot glue guns are not for funiture repairs. It may be quick and easy, but don't do it.

The wrong glue and too much of it.

Now a word about wood filler. It seems like a great idea to fill a crack or damaged area with wood filler, and that's indeed what it's for. But - you wouldn't believe how this simple material can create such ugliness. And - not all fillers are created equal. The wood filler a painter may prefer is generally not the wood filler a woodworker will use. If you're going to use filler, use quality material. Many fillers can be purchased pre-tinted in many colors and then sanded and blended in. Please, do not dump filler in, smooth it over with your finger and then leave it. Take the time to sand and finish properly. The results are worth it. Also - never use caulk as wood filler. I encounter this all too often.

This filler might have been effective if applied correctly.

Now, of course, this isn't an exhaustive list what you shouldn't do if you're going to repair your own furniture. It's always best to consult a professional, but I understand as well as anyone the desire to do it yourself. To insure that your repair lasts (and to make it easier for the next person who has to fix it), take the time to do it right or take it to someone who will. Don't drive a nail into your antique table. Don't screw a metal bracket into your grandmother's chair because it's getting weak joints. It's the wrong thing to do. Please... respect your furniture.

Today I pulled 38 staples out of a table leg and spent another half hour chipping out caulk and epoxy. This was after pulling out 14 nails. Guess how much of that was there originally? None of it! And none of it is there now. And it's strong and beautiful once again.

Let the Blogging Begin

I've finally entered the blog world. To some it may seem strange to blog about woodworking, restoration, refinishing, and furniture repair work - but this is my profession and in many ways my passion.

The nature of my work has certainly evolved in an unexpected direction over the past couple of years. I never expected to be so heavily involved with water damaged furniture, but that is unavoidable in post-Katrina New Orleans. In fact, the storm created a lot of business for me. It took me a long time to get comfortable with that idea since so many people suffered and lost so much. As time as passed, I've found (or at least convinced myself) that I am, in some small way, moving New Orleans forward towards recovery. Some people are building houses, cleaning up debris, etc., and I am bringing back the furniture.

It's such a small thing, but I am continuously enchanted by how attached people are to their furniture. I've been in a lot of houses that were completely gutted - just an open space interrupted by moldy 2x4's and that all-too-familiar smell Katrina left behind. Often the only things left in the house are a pile of furniture (or parts of furniture) that the owner managed to salvage. For many, these pieces are the only thing they have to connect them to life before the hurricane. As you can imagine, I've heard a lot of stories. I wish I would have documented them as I heard them as they have been truly fascinating. It has connected me with my customers in a way that I don't think would happen anywhere else. We're all moving slowly towards a sense of normalcy in New Orleans, and if a restored piece of furniture helps some get closer to that, then I've done my part.

For now, it's back to the wood shop. Every week is different here and presents new challenges. This week it's the restoration of a flooded armoire, refinishing an old dining set, and various small repair jobs.