Journey of The Rib
Here’s the journey of "The Rib" and the process behind its creation. From initial design concepts to the meticulous shaping of each ash strip, every step was a labour of love. By carefully breaking the grain, utilising precise clamping techniques, and employing innovative methods to ensure a seamless fit. This project reflects our commitment to craftsmanship and sustainability, culminating in a piece that beautifully blends form and function.
To improve the fit of the ash pieces into the CNC-cut slots, consider modifying the slot design by slightly increasing their dimensions or adding a chamfer to ease the insertion. Beveling or pre-sanding the edges of the ash pieces can also help them slide in more smoothly.
It's beneficial to perform a dry fit test before the final assembly to identify any tight spots and avoid damaging the plywood. Additionally, ensuring the plywood has optimal grain orientation and using a suitable CNC bit can reduce the likelihood of chipping and make the assembly process more efficient.
I’m using a hand chisel to carefully remove some excess plywood for a better fit.
To ensure the ash strips remain secure during assembly, I applied expanding glue while the wood was still wet, just before taking it out of the steam box. This creates a strong bond and prevents any movement as the wood dries and sets.
After removing the ash strips from the steam box, I pre-bent them over my leg to begin breaking the grain before placing them into the plywood jig. This initial flexing helps the wood conform more easily to the desired shape in the jig.
After breaking the grain, I worked with Dave to carefully position the ash strips into the jig. We clamped each strip securely in place and used a nail gun to fix them into the plywood, ensuring a precise fit and stable assembly.
Here's an up close detail of the clamping.
I used a block to help maintain a more natural curve in the wood. This technique provided support and encouraged the ash strips to bend smoothly, ensuring a better fit within the jig.
