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Old World Furniture - Coffer Project
The linenfold coffer is the one of the newest additions to the Old World Furniture lineup.
It is a reproduction of a wonderful small chest which probably dates from the mid sixteenth century. It is a fine
example from the Tudor period which often incorporated the linenfold design where wood was carved to look like folds
of linen fabric. It measures 28¾"W x 14¾"D x 18¼"H.
The photos and descriptions below detail some of the steps taken to
build our linenfold coffer. They depict the level of craftsmanship
which is typical for all our historic reproductions.
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The edge of the lumber is joined, the sides are planed, so that the stock is flat and square. Only then can it be accurately cut to size. The stiles and rails are just over 1¼" thick. This coffer will have great strength. Note that the tendons have also been rough cut on the ends of the stiles and rails.
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The mortises are carefully laid out, cut, and finally hand trimmed. The mortise and tendon joint is one of the strongest joints in woodworking. During the Middle Ages, craftsman who specialized in preparing these joints, were called
"joyners”
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The tendons are carefully hand pared for precise fit in the mortises. The accuracy of the fit and the strength of the joint is determined by the skill of the craftsman in this process.
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To test the fit, the joints are gently tapped together. If the joint is too tight, additional paring is in order. The proper fit is just snug, but not too tight, for maximum strength. There needs to be just a little room for the glue.
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Wood for the panels is carefully selected so
that the grain patterns add to the final beauty of the piece. Panels are measured, cut, and trimmed to fit into the frames.
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The lid is dry assembled, checked for fit and squareness. Now for the first time, the beauty of the lid is beginning to be visible.
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Following the same steps, each piece of the coffer frame is pared and fitted together. When they are dry assembled, the coffer’s size and shape come together.
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The coffer is disassembled, the panels are cut, rabbeted and fit into each individual frame. The coffer is reassembled with panels dry fitted in place. This is the point to check grain patterns for a pleasing appearance.
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The front panels for the linenfold pattern are removed from the frame. The pattern is laid out directly on the wood and the removal of stock begins. Many successive cuts begin to reveal the intricate details of the linenfold pattern. Linenfold was very popular
from the early Middle Ages through the Tudor period. The skill of the carver will be on display on the front of the coffer.
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The coffer is once again reassembled with the linenfold panels in place. Each joint is carefully inspected. Now is the time to make any adjustment to the fit of the frame and panels. After pausing to admire the beauty of the piece, it is ready for final sanding.
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Once again, the coffer is disassembled. Hand sanding removes any marks left by the joining and planing process. The corners are sanded to a soft radius. The care and quality of the sanding will have a dramatic effect on the quality of the finish.
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After a final dry assembly and checking, the coffer is disassembled for the last time. Glue is applied to the mortise and tendons, but not to the panels—they remain unglued within their dados to allow for the panels to expand and contract with temperature and humidity changes.
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The clamps are properly tightened, producing a strong joint. Excess glue is removed, allowing the wood to receive the stain evenly for beautiful color. The rest of the frame and panels are glued and clamped in the same manner.
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A hole is drilled into the mortise, through the tendon, and through the mortise. This is the preparation for a “pegged” joint that is unable to loosen or come apart.
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An oak dowel is glued and driven through the
frame, locking the joint together. After the glue dries, the dowel
is trimmed flush and lightly sanded. This joint will remain rock
solid for the life of the coffer.
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To set the hinges in the same manner as the original is a labor intensive process. A mortise,
at a mere 3/32 of an inch wide, must be cut over 1 inch deep. The end result is a
hinge, ingeniously set at a 45 degree angle without any strap showing. Later a steel pin will intersect the strap through the wood, to lock it in place.
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Often the word “stain” is used for any color added to wood. Actually, this is a dark brown walnut dye being applied. Dye does not have any sediment in the bottom of the container which has to be mixed before use. Dye allows all the natural beauty of the oak’s grain to be enhanced, not obscured.
It's more work, but it yields superior results.
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The surface is flooded with finishing oil and allowed to soak-in for a few minutes.
After that, the excess is wiped off and the piece is vigorously
rubbed until a soft sheen appears. On the second and third day, the process is repeated. The beauty of a hand rubbed oil finish is considered by many to be second to none.
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Steel pins are inserted to set the hinges in place. The escutcheon is nailed in place. Final highlights are artistically added to make the piece resemble
one that has been well cared for in a fine museum. After a meticulous final inspection, the paneled coffer will be ready for delivery.
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