Shop Workflow & Batching
Jig Production
A jig converts a single precise setup into a repeatable process. A stop block on a crosscut sled cuts 20 identical lengths as easily as one. A taper jig cuts 8 tapered legs identically without re-measuring. Router templates with flush-trim bits reproduce complex curved shapes endlessly. Professional woodworkers spend as much time designing jigs as executing cuts — the jig is the product that makes the product.
Dust Collection
Fine wood dust, especially hardwood dust, is a class 1 carcinogen. A two-stage cyclone separator removes 95% of dust before the filter, dramatically extending filter life and preventing fine dust bypass. Connect every stationary machine via 100mm PVC pipe to a central collector. HEPA filter the shop air after collection — the finest particles are invisible but most damaging.
Sourcing and Lumber Geometry
The Lumber Yard
Lumber is sold in "Quarters" — thickness in quarter-inch increments. 4/4 (four-quarter) = 1 inch rough, yielding approximately 19mm finished. 8/4 = 2 inches rough. 12/4 = 3 inches rough. Buy from a hardwood dealer, not a DIY store, for fine furniture work. Select boards in person — inspect grain, check for hidden defects, choose for colour match.
Cut Lists and Board Feet
Board feet = length (inches) × width (inches) × thickness (inches) ÷ 144. A cut list specifies every component with final dimensions. Add 20–25% to the cut list total for defects, milling waste, and setup pieces. Cost the lumber before ordering to confirm the project budget is viable.
The Business of Fine Furniture
Pricing Formulas
Materials + Shop Rate (hourly) + Overhead + Profit Margin = price. Shop rate must cover tool depreciation, insurance, electricity, and any rent. Minimum viable shop rate in the UK: £25–40/hour for hobby-to-professional transition. Experienced craftspeople charge £60–120/hour. Never price on materials alone.
The Commission Process
Secure a 50% non-refundable deposit before purchasing materials — this covers materials and initial design time. Balance due on delivery. Provide a written agreement: species, finish, dimensions, delivery date, payment schedule, what happens if the client changes the brief mid-project. Manage expectations around wood variation — no two pieces of wood are identical.
Portfolio Photography
Natural side lighting reveals texture and surface quality better than flash. A polarising filter on the lens cuts reflections on polished surfaces. Shoot against a neutral background — white, grey, or stone floor. Process in Lightroom to restore neutral colour balance and enhance grain. Your portfolio is the primary marketing asset — photograph every significant piece.
The Gallery Commission
Design an original piece of fine furniture — a cabinet, writing desk, or complex chair. Draw comprehensive plans with dimensions. Generate a professional cost estimate. Source the lumber. Build the piece using at least three distinct joinery types. Apply a professional finish. Photograph for your portfolio.
Success criteria: Plans are complete and dimensioned. Cost estimate accounts for materials, labour, and overhead. Three distinct joinery types are identifiable in the finished piece. Finish is consistent and professional throughout. Photographs are well-lit and portfolio-ready.
Phase 6 Practice Exercises
12 exercises to build skill through direct application.
Build a Stop Block Jig
Stop block for crosscut sled. Cut 10 identical pieces to verify consistency.
- Jig construction
- Repeatability verification
- Tolerance checking
Build a Taper Jig
Taper jig for table saw. Cut 4 identical tapered legs.
- Jig geometry
- Consistent taper
- Leg matching
Router Template
MDF template for a curved shape. Rout 3 identical copies with a flush-trim bit.
- Template construction
- Bit selection
- Copy consistency
Cyclone Dust Collector
Build or install a two-stage cyclone. Connect to primary dust source.
- Cyclone setup
- Pipe connection
- Suction verification
Lumber Yard Visit
Visit a hardwood dealer. Select and purchase lumber in person, hand-selected.
- Species identification
- Defect reading
- Colour matching for projects
Cut List and Board Feet
Write a full cut list for a simple table. Calculate board feet including 25% waste.
- Cut list discipline
- Board feet maths
- Waste factor application
Price a Project
Calculate full price for one completed piece: materials + labour + overhead + profit.
- Pricing maths
- Overhead identification
- Profit margin setting
Draft a Commission Agreement
Write a commission agreement for a furniture commission with all clause types.
- Contract clause writing
- Rights and expectations
- Payment structure
Portfolio Photography
Photograph three completed pieces with correct lighting. Process in Lightroom.
- Lighting setup
- Camera settings
- Lightroom colour correction
Portfolio or Instagram
Create or update a portfolio website or Instagram with 6 best pieces.
- Curation discipline
- Presentation consistency
- Online presence
Material Cost Audit
Calculate exact material cost of most recent project. Compare to estimate.
- Cost tracking accuracy
- Estimate vs actual
- Margin analysis
Year Review
Review all six milestones. What has changed? Where do you focus next?
- Progress self-assessment
- Skill gap identification
- Goal setting for year 2