Step 1. This photo shows a 1.5” x 1.5” x 12” turning square of Brazilian kingwood, a true rosewood, being cut from a small log.
Step 2. This is the turning square ready to mount in the Legacy Mill. I wish you could enjoy the wonderful smell of the rosewoods as they are machined; every one of them is distinct and lovely. If you purchase Nadezhda, you will receive a little bag of kingwood shavings in the box so you can appreciate this for yourself.
Step 3. I have to fill this crack with cyanoacrylate glue (Superglue). We have pint bottles of this stuff in the shop.
Step 4. The turning square mounted on the on the Legacy Mill. Remember that I always do the twist first and then think up a crown and base.
Step 5. The square is turned round using a flat bit in the router.
Step 6. The turning square is now round but a new hole has been revealed that will require more cyanoacrylate.
Step 7. A barley bit is used to make a grove at the top and bottom of the twist.
Step 8. One of the completed grooves.
Step 9. The barley bit has been used with a very short pitch to make this corkscrew pattern.
Step 10. The completed twist. Now it is time to sit in my shop chair and stare at the wall until I come up with ideas for a base and crown. We may be here a while.
Step 11. This is the Incra sled on the table saw that allows for precise cutting of pieces for segmented rings. For Nadezhda, there will be three 24-segment rings of maple burl.
Step 12. There should be another photo before this one… Suffice it to say that the three maple rings were propped up one side as they were run through the drum sander, so that their tops became slanted. A flat piece of purpleheart was glued to the maple rings and then the assemblies were run through the drum sander again, leaving a wedge of purpleheart on the top of each ring. See the next photo for a side view. Finally, the three rings were glued together and then cut apart vertically on the band saw.
Step 13. These are the two parts of the ring assemblies showing the purpleheart ‘darts’. The rings are temporarily mounted on a piece of scrap pine.
Step 14. The two parts have been glued back together with a little pernambuco board between them and all of that has been glued onto an ebony base. A complex sandwich of ebony, purpleheart, and pernambuco has been glued on top.
Step 15. The base has been turned on the lathe and now you can appreciate the purpleheart ‘darts’, the pernambuco separator, and the sandwich. A hole is being drilled in the top to accept the tenon from the twist.
Step 16. Here, for the first time, is revealed the secrets of Ferry's Zigzag Joint. It all starts with cutting an even number of diamond-shaped indentations in the side of the twist. The regularity of this is assured by the indexing feature of the mill, for you technical types.
Step 17. The 12 diamond-shaped grooves in the twist can be seen as the piece is mounted on the lathe.
Step 18. This is the same result in a short piece of pernambuco. The cuts in the two pieces MUST be identical.
Step 19. All but the points at the edge must be carefully removed on the lathe.
Step 20. These two sections of the joint must align perfectly or one or both needs to be made over.
Step 21. Amazing! It is always extremely gratifying to have these match up. Now they just need some epoxy glue.
Step 22. Three more segmented rings of kingwood and pernambuco were constructed for the crown. Not shown here is the 12-sided stave assembly of kingwood and maple burl that will also be part of the crown. See the next photo.
Here are all of the parts of the candlestick– the base, the three rings for the crown, the twist with Ferry’s Zigzag Joint, and the maple-pernambuco stave assembly for the crown.
Step 23. This is the assembled crown with 12 vertical staves, the three segmented rings, and pieces of blackwood above and below. Note the black veneer between the staves.
Step 24. The twist has been glued to the crown.
Step 25. The crown has been turned and is being sanded.
Step 27. The completed crown. It is for the creation of beautiful things like this out of woods that are so stunning that I am drawn back to the shop over and over again.
Step 28. The tenon has been cut on the other end of the twist (see the glossary if you need a refresher on the definition of a tenon).
Step 29. Down to only two sections.
Step 29. Finished, except for the finish, which will take as long as the entire construction has. Woods- ebony, Brazilian kingwood, pernambuco, maple burl, purpleheart. Number of pieces- 169. Features a a single barley twist with a short pitch, Ferry's Zigzag Joint, and the rosewood Brazilian kingwood. Because pernambuco is listed in CITES Appendix II, this candlestick cannot be sold out of the United States.
Step 31. Nadezhda after 5 coats of spray-on polyurethane. The finish really makes the beauty of the wood more vivid as well as adding protection against wear and tear. I use an exterior grade polyurethane that incorporates ultraviolet light blockers to retard fading and darkening.