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From Timber to Masterpiece
Selecting the Perfect Piece of Timber
- Timber Selection: We hand-pick premium sustainably sourced wood for every project.
- Precision Cutting: Each piece is meticulously measured and cut to exact specifications.
- Master Joining: We use traditional joinery techniques to ensure lasting durability and strength.
- Hand-Applied Finish: Every item is sanded and sealed by hand for a flawless, protective coat.
Building the Form and Molds
- Designing Mold Shape: We start by mapping out the exact dimensions and unique contours required for the pour.
- Building the Frame: A sturdy, leak-proof frame is constructed to hold the resin securely in place.
- Sealing & Preparing: Every joint is sealed and the surface is prepared to ensure a flawless release after curing.
Pouring the Epoxy Resin
- Mixing Resin: Combine resin and hardener slowly and gently to avoid air bubbles.
- Adding Pigment: Stir in your chosen colors until the mixture is uniform and vibrant.
- Pouring into Molds: Pour in a steady stream into the center of your molds for a clean finish.
The curing and Removing the Form
- 7-Day Curing: We let the piece rest undisturbed for a full week to ensure the resin reaches maximum strength.
- Gentle Removal: Each item is carefully eased from the mold by hand to preserve every sharp edge and fine detail.
- Final Inspection: Once removed, we perform a close-up check to ensure a perfect, bubble-free finish.
Re-Flattening & Surfacing
- Leveling the Surface: Check for high spots and run the piece through a planer or surfacing sled to remove any irregularities.
- Flatness Check: Use a straight edge to confirm the surface is perfectly flat and consistent across the entire length.
- Final Preparation: Once dead-flat, proceed to final sanding to ensure a smooth, professional finish before oiling.
The Finishing Steps for a Smooth Surface
- Initial Sanding: We carefully sand the surface to remove machine marks and smooth out any rough patches in the timber.
- Raising the Grain: We apply a light mist of water to pop the wood fibers, ensuring they don't swell later under the finish.
- Final Sanding: Once dry, we perform a final high-grit sand to flatten the raised grain, leaving the piece silky smooth and ready for oil.
Final Handcrafted Touches
- Perfecting the Edges: We carefully soften and detail every corner for a comfortable, professional feel.
- The Final Finish: A protective, hand-applied finish is used to seal the wood and bring out its beautiful natural grain with Rubio Monocoat Oil Plus 2C
- Final Inspection: We perform a close-up quality check to make sure every detail is perfect before it leaves our shop.
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