Intarsia Yves Laforest
Wood, nature's gift
INTARSIA
What is intarsia? A simple answer: it's like stained glass, but with wood... Personally, I first saw intarsia at an exhibition of La Foire du Bois at St- Hyacinthe. I bought (among other things) a book about making wooden padlocks. This book cost me over $4,000.00 ! It came with a table saw, a planer, a thickness planer, a scrollsaw, a press drill, two sanders and a lot of wood !
The way a piece of intarsia is made will vary a little from one craftsman to another. Here's how I do it, in 6 steps:
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Let's see those steps in more detail.
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Wood choice
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In my intarsia pieces, no stains or paints are used. The colors will be chosen according to the different wood species; white, red, brown, orange, mauve, etc. Currently, I work with around thirty different species.
Next, I look at the texture of the wood. If I want a lined (or ribbed) appearance, with dots (piqué), waves (curly), with reflections, etc., I can choose a wood species that will offer this kind of detail.
You can see some examples below. To see a lot more, you can go to the site of the St-Eustache exotic wood store www.bois-exotique.com) or Ottawa KJP Hardwood (https://kjpselecthardwoods.com).
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Parts cutting
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Once the essences have been chosen, we move on to cutting. Personally, I start with a plan on paper from which I cut out each piece. Then I glue each piece using a temporary glue (much like Post-It) on a piece of wood and I cut it out using a scroll saw. This is a saw that uses very thin blades which allow you to cut very precisely. The saw I use is an Excalibur with 30 inch throat; that means I can carve parts up to 29 inches in length from it. 29 inches is not that long when making big parts.
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In some cases, when the workpiece is long and the cutout is relatively straight, I will also use the bandsaw. Since it cuts much faster, it saves time but you lose a bit in precision.
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From beginning to end, I have to make sure that all the pieces fit together as perfectly as possible.
Shaping sanding
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The pieces are cut out. Excellent. We now have a "flat" piece which has no relief. At this stage, the piece is not of great interest… Using a belt sanding machine (opposite) with a fairly agressive sand paper, I will sand the piece to give it the relief I want to have; I'm going to make a dent here, give an angle there, etc. After this, the piece will be three dimensional.
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In the example below, we can see the wolf head before shaping (left) and after this step (right)
Finish sanding
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During the shaping sanding, I used a fairly aggressive sand paper which removes a lot of wood but also leaves a lot of streaks in the wood.
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At this point I will go to the sandblaster which uses a pneumatic cylinder with fine sandpaper sleeve mounted on it. Gradually, I will sand to remove the streaks and give the piece a silky appearance.
Assembly
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Finally, all the parts have been cut and sanded. The assembly process is a fairly simple step but it still requires precision so that everything fits together perfectly.
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I cut a piece of very thin plywood or "lauan" which will serve as backing. I glue all the parts there, hold them in place with metal weights and let everything dry for 5 or 6 hours. Then I go back to the scroll saw to cut out the backing piece following the outline of the piece and then go to the router table to make a 45 degree finish cut. Sand the outline and the piece is ready for finishing.
Final step
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Like a large percentage of craftsmen who work with wood, this is the step that I like the least...
Personally, I finish the piece by spraying a few coats of lacquer with a light sanding between each layer. This gives a nice, slightly glossy finish.
After adding a hook and placing a groove on the back, the piece is ready to go to the wall! Et voilà!
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