The Router Bit Contest Winner is Brett J.
Your reproduction of a late 1800′s hand carved, fireplace mantle is the winner.
Brett’s Woodwork Description
This is a reproduction of late 1800′s hand carved, fireplace mantle. The overall dimensions measure 11′ 5 1/4″ tall x 9′ 1 1/2″ wide. The original was built in England out of oak. Our reproduction was built out of solid Honduran mahogany, harvested from trees knocked down in Hurricane Felix of 2007.
Besides the overall design and carving, which was all done by hand, one of the biggest challenges in this piece was designing how various elements would fit together and allow for wood movement, as many of the pieces have opposing wood grain. Floating dovetails were often used to accomplish this and many of the pieces float within grooves – similar to solid wood cabinet door construction.
We got very good at cutting coves on a table saw to match moldings from the original. The mantle was built in Nicaragua and took over nine months from start to finish. It was installed in a private residence in St. Louis, Missouri in April of this year. It came apart into nine separate pieces and shipped in seven crates.