Hi. I have an ash dresser with an interesting detail for which I’d like to get more information: The top of the dresser is made from two boards of 5/4 #2 common ash and is very highly figured because of several knots. The interesting thing is the fact the centers of these knots were actually removed and the resulting void was then filled with a piece of matching color and similar grain that’s an exact shape of the piece that was removed.
The joint is miniscule and one must look very close indeed to even see what was done. These inserts are about an inch to an inch and a half in diameter, but are not perfectly round; they’re not exactly oval either, but are more oval than round. Does anyone know how this is done? Is there a template or a jig on the market that can do this type of work?
I’m interested because the common grades have better figure and were it not for the knots, much wider material could be incorporated into my projects. Thanks!
Replies
What you describe is a common repair technique. I will bet the patches are oval with the grain. (The smallest distance is across the grain.) Oval tends to blend much better than a round patch. While the existing knot can be scroll sawed away on small boards boards, the process is usually done by drilling out the knot then using a rasp to enlarge the hole to oval. I usually file a bit of draft (slope) into the resulting oval making the hole bigger on what will be the side that is inside. You now trace the hole onto a piece of wood of matching grain and species, cut and disk sand your plug to shape. (You can tilt the table on your disk sander to the same draft angle you filed.) After trial fit and refining to a perfect fit, glue and tap home with a hammer. On new work you can usually use the end of the board to get your patch.
In woods like cherry where the knots are black and you have a dead knot that fell out, but the wood is otherwise sound, you can tape one side with masking tape and fill the void with clear epoxy. Once sanded smooth brush black India ink over the patch and it will look like a sound knot.
It is possible to buy spring loaded punches of a wavy irregular shape for patching veneer. You simply punch over the damage then punch the patch from a like piece of veneer.
Antique restores have been know to chisel a piece from the bottom side, directly below a damaged area, of something like a table top and piece it into the damaged area. You lay out a square or rectangle over the damage. (Diamonds are very good as they hide more readily.) Through careful measurement you transfer this measurement to the other side. Thoroughly wet, and even warm with a household iron (producing a bit of steam is good), the area of the patch to be removed. Chisel out a thin (about 1/16") patch from within your layout lines. Wetting and steaming the area allows the patch to be chiseled up and out without the wood breaking. Now chisel a similar area (but not quit so deep) out from the damaged side. Glue in the patch clamping it in place with a waxed board over it. You can get a surprisingly good repair because of the good grain match.
With best regards,
Ernie Conover
Edited 10/6/2006 12:56 pm ET by ErnieConover
Edited 10/6/2006 7:07 pm ET by ErnieConover
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