The "Big Ass" Desk

About a year ago we received a request for quotation for a number of furniture pieces going into a large custom project. One of the pieces quoted was for a custom desk.

At the time I remembered feeling just a little bit nervous about the prospect of making a massive one piece curved top that would measure almost 14' corner to corner. Not knowing whether the quote would actually materialize as an order, I didn't end up spending too much time figuring out how, exactly, we'd do it.

Well, the order did materialize, and we did figure out how to make the top.




This is the credenza that will be located on the left side of the desk. There are a total of 6 box drawers over 3 files drawers. The drawer boxes will all be dovetailed solid maple running on Blumotion self closing linear ball bearing slides.




This image shows the addition of the side cabinet for CPU storage. There will be a removeable angled back added to this cabinet to allow for wiring access.




The curved modesty panel is bolted to the CPU cabinet.




The end gable is added to the far side of the modesty panel. The removable panel for the CPU cabinet can be seen on the right.




The "big ass" top is added to the "big ass" desk. It goes without saying that putting an undercut bevel edge around all 3 sides was more than a little challenging.




This view shows the inside of the desk, including the knee space.




I'm not certain whether this is the biggest desk we've ever made, but this is definitely the biggest desk we've ever made for a home office.

This piece has now been disassembled for sanding and finishing.

Custom Commission - Kidney Shaped Desk

What follows is a series of photos of a recently completed custom commission for a Kidney Shaped Desk. These images will form the basis for a series of blog posts that will explain this desk in great detail, explaining not only the various holistic woods used but also the process for making the gold, copper and silver inlays that have been fitted into the pencil drawer.




This is the initial walnut blank with recesses cut to receive the gold, copper and silver inlays. After the inlay work is complete this piece will become the lid of the box located inside the pencil drawer.




The gold and silver inlays were cast using a lost wax process. This image shows the mold and wax casting for the silver Turtle inlay.




The mold and wax casting for the Eagle inlay, which ended up being made of gold.




Benchwork on the Turtle inlay.




Benchwork on Eagle inlay.




Cleaning the casting of the Eagle inlay.




Polishing the Eagle inlay.




Handscraping the copper Tree inlay. Since it is not practical to cast copper, this inlay was made of bar stock that was seamlessly soldered together.




Preparing to fit the inlay into the wood.




After much polishing and finessing by hand, the final fit is achieved.




The wood lid can now be sanded in preparation for gluing the inlay into place.




A protective Lanolin finish is carefully applied by hand to the Black Walnut lid and sculpted inlay pieces that will function as finger pulls under the drawers. It is highly relevant that these pieces are all located in areas that will be frequently touched, since this will allow the active holistic molecules of the Black Walnut wood to come into direct contact with the skin of the person using the desk.




The finished lid and finger pulls, ready to be fitted into desk.




Front view of the completed desk.




A closer view of the end detail of the desk.




Detail view of top, showing Macassar Ebony top apron and inset of black Tuscany leather.




Detail view of side drawer.




Pencil drawer - closed.




Pencil drawer - open.




Interior of pencil drawer, showing inlaid lid of Black Walnut. The trays on either side are made of Sassafras, which is a holistic wood known for its aromatherapeutic properties. The box portion below the inlaid lid has been crafted from a wood called Hawthorn, which is also known for its aromatherapeutic and Ayurvedic properties.




Detail view of inlaid finger pull below one of the side drawers. The finger pulls are made of a special cutting of Black Walnut wood, which has traditionally been used by Native American medicine women for its holistic properties.

The properties of all of the holistic woods, and the story behind the gold, copper and silver inlays in the lid, will be explained in greater detail in a subsequent post.

Custom Writing Desk - (Part 6) - The Completed Desk

With the finishing process now complete the desk can be assembled.

The completed desk is shown as follows:




Front view of desk.




Front corner detail.




Rear view of desk.




(I love this) detail of where the drawer meets apron.




Drawer open, showing dovetails.




Inlaid grommet in desk top.

Custom Writing Desk - (Part 5) - Finishing the Desk

Most woodworkers will tell you that the most tedious part of the furniture making process is the hours of final sanding required to prepare the wood for finishing.

In my mind this stage is actually quite exciting, because it helps me to anticipate more clearly what the finished piece will look like.

In the previous post the solid cherry received multiple coats of a vinegar and iron solution, which is the traditional way of ebonizing wood to a darker colour.


A black toner is then applied to ebonize the darker areas more consistently.


At this stage I am extremely pleased with the decision to add the beading details to the aprons and drawer fronts.

The Macassar Ebony looks incredible!

Next: Custom Writing Desk - (Part 6) - The Completed Desk

Custom Writing Desk - (Part 4) - The Making of the Desk Begins

With the drawing and finish sample now approved it is time to proceed with the actual making of this custom desk.

First the Macassar Ebony veneer is carefully cut and bookmatched, before being laminated to rigid veneer core Birch plywood panels.


The aprons are double laminated for strength, and solid corner blocks are added to receive the legs. The front legs (alongside where the drawers will be) are going to be mechanically secured with steel hangar bolts.


Pipe clamps hold the framework square while the glue sets up.

The desk legs are milled out of solid 12/4 Maple stock.


These solid cherry bead details will be added later to the underside of aprons and drawer fronts.


This view shows the pocket that will receive the dovetailed drawer boxes. The legs are also bolted in place.


The Macassar Ebony apron showing leg and beading detail.


With the woodworking portion nearly complete the desk is stood upright to verify proportions, fine tune the details and ensure stability.


Front corner detail showing drawer closed.


Drawer open.


At the intersection where drawers meet centre apron the beading detail helps accentuate the lines.


The desk is now disassembled and ready for sanding and finishing. At this stage a traditional vinegar and iron solution is applied to the solid cherry to naturally darken the wood. This solution reacts with the natural tannins of the wood to achieve the ebonizing effect.

Next: Custom Writing Desk - (Part 5) - Finishing the Desk

Custom Writing Desk - (Part 3) - Finish Sample for Approval

In tandem with sending drawings to the client for approval I always like to make actual finish samples of the wood we intend to use. This helps clear up any misunderstandings that might take place regarding what the finished wood surface is going to look like.

For this particular Writing Desk a bundle of quarter cut Macassar Ebony was selected, and after confirming the yield a portion was cut and glued to a piece of plywood.

After sanding and lacquering the full panel was then cut into smaller squares, with the edges being sanded and slightly bevelled. The backs of the samples are then covered in felt, and a labelled to identify the project, wood species, type of finish, and date.


Two of the samples are then sent to the client, with copies kept as control samples in our shop.

Once we receive client approval on these samples, the woodworking on the desk can begin.

Next: Custom Writing Desk - (Part 4) - The Making of the Desk Begins

Custom Writing Desk - (Part 2) - Scale Drawings

The next step is to take the approved design concept and turn it into a scale drawing, which will give a better idea of what the finished desk will look like.

This drawing can then be submitted to the client for approval.



Once the drawing is approved we can select the appropriate material and make a finish sample for approval.

Next: Custom Writing Desk - (Part 3) - Finish Sample for Approval

Custom Writing Desk - (Part 1) - Conceptualizing the Design

Recently an Internet inquiry came through asking about how to commission a custom writing desk. After some preliminary discussions about various designs including the Kidney Shaped Desk, Rainforest Desk and 1927 Console/Desk it was determined that a customized version of the latter might be most appropriate for the required dimensions of 55" long x 22" deep x 30" high.



Based on this discussion an initial concept was sketched out and emailed to the client. As a starting point this design has curved, tapering legs and a bowed apron with elevated ribs to support a Macassar Ebony top. The fact that the cross ribs are elevated helps creates the visual illusion that the top is floating.

Although I thought the idea was quite interesting and unusual, the client didn't like it. After further discussion the design was revised as follows:



This idea the client loved. At this point we formalized the pricing with a written quotation, and a deposit was made so we could then make the scale drawings required to finalize the concept and work out the details.

Next: Custom Writing Desk - (Part 2) - Scale Drawings