The shape of the desk came about after several conversations and design iterations with the client to make sure the ergonomics and aesthetics were both just right. Here's the concept drawing and rendering that I gave the client (you'll notice that the middle leg moved in the final piece) ....
The construction process turned out to be a lot more involved than I had anticipated, taking more than 150 hours, but I think it was time well spent.
Here's some of what went into it....
The desktop is made as a torsion box. Half inch thick birch plywood skins were glued over a corrugated cardboard core by means of a vacuum press.
Th photo also shows the electric blanket that I cover the press with to keep everything warm enough for the glue to set correctly. The top and underside were each covered in single large sheet of burl, pressed separately.
The two curved skirts were laminated, on dedicated bending forms, from 1/8" layers of solid wenge.
The legs are elliptical in cross-section at the top, and taper to a circular cross-section at the bottom. They started as square billets which were then tapered and roughed out on the bandsaw.
Then final shaping was done by hand with planes, scrapers and sanders.
The legs are grooved to fit over the skirtboards. They are then through-bolted to the skirts for extra strength. They were made to be removable to facilitate easier delivery.
Clamping the edge and perimeter banding took some creativity, given the complex shape of the top.
The desktop shaping and perimeter banding required several templates.
The desk also includes a round pivoting drawer.
In the end, I think it came out really well. My thanks to Paul Scraub for the studio photos.
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