1) The first method we use, is call the "Bonded Method."  With this method the wall is formed using a high quality redwood, cedar, pine, fir, or the wood of your choice with the outside layer being vertical, horizontal, diagonal, or whatever and the inside being 90 degrees to the outside layer, which provides a very strong, very heavy  wall, usually 1 1/4" thick.  We usually use this method when the inside walls are not visible all the time, such as with sideboards, hutches, island storage compartments, etc.  But, if a door is left open, the view is still very pleasing.

2) The second method is called the "Overlapping Method."  In this method the grain of the walls, inside and out,  flow in the same direction, vertical, horizontal, diagonal, or whatever you please.  With this method, each board is covered halfway by the other layer until the desired size is reached.  This method is employed when the inside, as well as the outside, of the wall will be seen all the time, as is the case with lighted cabinets.  The beauty of this method is stunning.

3) We also use just one layer of wood to construct walls, by using a bonding technique similar to wafer bonding.  However, in our method the wafer is a strip of similar or harder wood which runs the full length of the boards to be bonded.  The strip is embedded in each piece of wood between 1/2" and 1 1/2" depending on the thickness and application. We use this method to make our table, desk, and sideboard tops, which are usually 1 1/2" to 6" thick, using this method on walls would make it weight prohibitive.

  So, to maintain the structural strength of the single board walls, they are bonded to supports top and bottom.  If the weight of the piece is a factor, we can reduce the thickness of the bonded or overlapping methods by 50% and still give our lifetime guarantee.  However, the single board construction carries no warranty.  It will split, or separate at the seams, but some of our customers like this, it's the way real western furniture was created,  and we are in the business of pleasing our customers.  So, if single board construction is your desire, you'll get it.

Our chairs, rockers, beds, and pole framed items, are assembled using the traditional  mortise and tenon method of construction.  In this method a tenon, or  wooden pen, on one piece is inserted into a mortise, or hole, on the other piece.  The mortise and tenon are the same size making the bond very tight.  To ensure the tightest bond possible, the joint is then assembled using an expanding polymer, or glue, which fills any voids in the joint.  We then secure all structural mortise and tenon connections with galvanized bolts.  The seats of our chairs and other board to pole connections are made using zinc coated screws.

So, you decide on the method that is right for you.  But lets be frank about one thing, custom furniture is not cheap.  You want cheap, there are hundreds of stores around the county, selling laminated particle board as solid wood rustic furniture, go buy that; but if  you are in the market for heirlooms that will last a lifetime, give us a call or send us an email.

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