HOW WE BUILD
YOUR FARMHOUSE TABLE
(Stained Classic Gray)
(Stained Classic Gray)
(Stained Dark Walnut)
OUR BUILD PROCESS
Probably the most important thing to consider when buying any piece of furniture is the material. All of our tables are constructed using hardwood materials and all of our hardwoods are purchased from a local, very reputable, sawmill. In fact, this sawmill supplies their products to companies all over the world.
We mainly use Oak, Maple, Cherry and Hickory. When available we also use other hardwoods such as Walnut and Ash. Why hardwoods? Durability and, believe it or not, safety.
We probably understand about the durability of hardwood, but safety? That's right! The most widely used material for furniture is presswood. In order to produce presswood, many harmful chemicals (according to experts smarter than us!) are used in the production of presswood. These harmful chemicals, as the furniture wears, can actually leach from the piece into the air of your home. Not to mention what happens if moisture permeates the surface. We've all seen the results of leaving water on a presswood surface.
Now to really understand the durability of real wood, its best to understand how wood is rated according to hardness. The industry standard is The Janka scale. The Janka rating scale was created to rank the various degrees of hardness throughout the different species of hardwoods. To find this number, a steel ball is pushed halfway into a 2” x 2” x 6” wood plank. The number of pounds per square inch (PSI) needed to push the steel ball into the wood determines the Janka rating.
Hickory has a Janka hardness scale rating of 1,820 lb.
Red Oak has a Janka hardness scale rating of 1,220 lb.
Cherry has a Janka hardness scale rating of 950 lb.
Soft Maple has a Janka hardness scale rating of 950lb.
Most of the lumber purchased at your local big box stores is pine, with a Janka hardness scale rating of between 380lb and 420lb. Great for building projects around the house, but not furniture.
After hand picking the boards for table construction, we process the wood to achieve the client's preferred finish. Some clients prefer like a clean smooth finish like the table top pictured below.
Many prefer a more distressed rustic look, complete with saw marks and maybe a few knots filled with colored epoxy and sanded smooth. For distressed table tops we recommend using only oak.
A quick look at the underside of our tables and you will see our method of constructing our (YOUR!) tables. Many manufacturers simply glue the boards together, then sand smooth for a smooth finish. We go one (we think!) very important step further. After gluing, we pocket screw the boards together for that added strength. These pocket screw holes are pictured below. Notice what appears to be a gap, between the boards in the picture below. This actually a line we cut to allow for wood movement, which we will explain a little further down the page.
Then it's time to sand, stain and polyurethane (3 nice coats). After completing the tabletop, it's time to fashion the table skirt, which we also construct from oak. Our standard 6ft x 3ft table weighs around 120 lbs., so it's vital the table skirt is constructed from the best material available! The table skirt and table legs are painted or stained and then, it's time for assembly.
We attach our tops using L-brackets which allow for wood movement. All wood moves, (think of real wood floors where gaps develop or wood trim which can separate at the joints during seasonal changes. Failure to use this mounting system is common mistake made by many DIYers and will result in cracked table boards and or major structural issues.
Then, it's off to the curing room, where the finish is allowed to cure and harden for about 2 weeks.
So there it is. Our Process.