From Forest to Finished: Our Complete Handmade Woodworking Process

How We Make Your Wood Decor: Our Step-by-Step Woodworking Process

Every piece that leaves our workshop tells a story. It starts as rough lumber and becomes a carefully crafted item for your home. Here's how we transform raw wood into beautiful, lasting furniture through our step-by-step process.

Sourcing Quality Wood Locally

We buy over 90% of our wood from local sources right here in Southwest Ontario. This includes farmers, small mills, and small businesses that supply both new and reclaimed wood.

Working with local suppliers gives us a big advantage - we get to know our materials. This is especially important with reclaimed wood, where we need to understand its history. All our reclaimed wood comes from Canadian sources and hasn't been treated with the harsh chemicals used in some other countries. Any pallet wood we use has been properly heat-treated for safety.

By building relationships with the same suppliers over time, we learn the story behind each piece of wood. This knowledge helps us create better products and ensures we're using safe, quality materials in our handmade woodworking process.

Preparing Raw Lumber

Most of our wood arrives rough and unmilled, which means it needs careful preparation before we can build anything. This is where the real work begins.

First, we cut the lumber down to manageable sizes. Then each piece goes through our jointer, a machine that creates at least one perfectly flat surface and one straight edge. This step is crucial because everything we build afterward depends on having accurate, square lumber.

Next comes the planer, which brings all our wood to a precise, consistent thickness. The planer also smooths the surface and reveals the wood's natural grain patterns and character.

Assembly and Construction

Once our lumber is properly dimensioned, we cut pieces to their final sizes and begin assembly. This is where craftsmanship really shows.

We use Titebond III glue, which is known as one of the strongest wood glues available. But depending on the project and wood type, we often add other fasteners too. This might be brad nails, screws, or traditional wooden dowels. Each method has its place, and choosing the right one depends on the stresses the piece will face.

Surface Preparation and Sanding

Great finishes start with properly prepared surfaces, so we take our sanding seriously. We begin with 80-grit sandpaper to remove mill marks and level everything out. Then we work our way up through finer grits.

Most projects get a final sanding with 220-grit paper. This creates a smooth surface that still has enough texture for stains and finishes to bond properly. However, cutting boards, charcuterie boards, and other food-contact items get special treatment with a final 400-grit sanding for an exceptionally smooth, food-safe surface.

We also use routers when needed to create clean, finished edges that add both beauty and function to our pieces.

Staining for Even Colour

Different wood species react to stain in different ways. Some absorb it evenly, while others can be challenging and may look blotchy without proper preparation. For difficult woods, we apply a pre-stain conditioner that helps create more uniform colour coverage.

Patience is key in our finishing process. After staining, we always wait 24 to 48 hours before applying any topcoat. This ensures the stain has fully penetrated and dried, preventing problems with the final finish.

Protective Finishes for Different Uses

The type of finish we use depends on how and where you'll use the piece. Each situation requires a different approach.

For painted and stencilled items, we start with high-quality chalk paint that provides excellent coverage and a great base for decorative work.

Our protective topcoats include:

• Polycrylic for indoor items and children's furniture. This water-based finish won't yellow over time and provides good protection for indoor use. While it's not durable enough for outdoor applications, it's our top choice when safety is important, especially for anything children will use.

• Varathane for items that need a little more support than polycrylic can provide. This finish offers excellent durability for high-use indoor pieces.
  

• Outdoor Varathane for exterior items that need weather protection. This finish is specifically designed to handle temperature changes and moisture exposure.
  

• Marine Spar for any item that will come in direct contact with water. This marine-grade finish provides maximum protection against moisture damage.
  

• Epoxy for special applications where we need exceptional durability. We use epoxy on items that will contain food (like some serving pieces) or need serious water protection like planters. Epoxy also allows us to add beautiful colour effects and decorative elements to our boards.
  

• Wax finishes offer a more traditional look and feel. They're easy to maintain and can be touched up when needed.
  

• Food-safe oil for cutting boards, charcuterie boards, and any hardwood item that will contact food. We use Walrus Oil, a blend of mineral oil, beeswax, and coconut oil that's completely food-safe. We recommend customers re-oil their boards monthly to maintain their appearance and protection.

We add three coats of every finish, which then requires 24 hours drying time in between.

Why Mostly Made to Order

We make most items to order because we believe you deserve something fresh and built to many of your specifications. This approach means you're not getting something that's been sitting on a shelf - you're getting a piece made specifically for you.

We also offer bare wood options for customers who prefer to finish their own wood. This lets you benefit from our precision milling and expert construction while adding your own personal finishing touches.

If you want something completely custom, especially for you, we have you covered there as well.

Why Our Process Makes a Difference

Every step of our process reflects a commitment to quality that goes beyond just making functional items. From carefully sourcing local materials to our methodical finishing techniques, we believe the details separate good woodworking from great woodworking.

When you choose our work, you're getting pieces that combine quality materials, proven construction methods, and careful attention to detail. These aren't just products - they're pieces built to last and be treasured for years to come.

Ready to discuss a custom piece for your home? Contact us to learn more about our process and how we can create something special for you.