In case you missed part one of the Dart Board Cabinet series, click here. Also, in case you are just tuning in, this is the finished project, but I like to show the step by step process of how I build things for clients. For this posting, I wanted to focus on the carving and wood burning on the doors, as that is the feature that really sets this dart board cabinet apart from something cheap you can get on Amazon. As is usual, I layout the size the letter full size in my CorelDraw X3 Drawing program, and print off multiple pages and piece them together to make the full size letter. You can see the “G” I carved for Jeff and Samantha, which is another example. I used graphite paper to transfer the paper pattern to the wood. The somewhat tricky part of carving this letter in particular was the wide “sweep” of the “H” uprights. They are quite wide. Mathematically, If I went in at the same angle I’d go through the 3/4” wood, but I had to carve it shallow and wide to compensate. Most letters are narrow enough to use my V tool, but this one was so wide I had to use multiple tools to make the letter.
Cutting across the grain was defiantly the best strategy. Pine has a tendency to split/splinter when you go with the grain. Going cross grain limits the breakage. On a dart board cabinet door, having a big split wouldn’t be very appealing. For something that had so many tool marks, I had to sand it quite a bit. A lot actually. Real quick, here’s a picture of the border that I routered/carved (apparently I only took one picture of it??) I took 3 passes with my bull nose router bit, and then used a really wide #8 chisel to carve out the other tool passes. On the back of the left door, Kelly and I decided on a design that incorporated the newlyweds date and names in a “subway” art type layout. My wife Jen actually designed it—she’s got a good eye for fonts and things (check out her Pinterest board here; she’s always pinning interesting things). On special request, Kelly asked that I put a sentimental sea turtle in a hidden place (I’m sure the meaning of the turtle was special!). Like the transfer paper process for the “H,” I transferred the above design to the door. To keep it short, here’s the pictures:
I decided to carve the newlywed’s last name “Hasse” into the inside of the door since woodburning those wide letters would look rather awkward. Plus, it breaks up the monotony of the lettering being burned into the dart board cabinet door.
Stay tuned for part 3 of 4 where I put the finish on and the final assembly!