A Custom Walnut Vanity

Nathan Clark

Because the existing cabinets use beaded face frames, the new va… Read More Because the existing cabinets use beaded face frames, the new vanity needed the same detail to feel fully integrated. At the router table, featherboards held the stock firmly against the fence and table, making it possible to cut the beads consistently.

Nathan Clark

The rails—the horizontal members of the face frame—required … Read More The rails—the horizontal members of the face frame—required extra attention, especially those dividing the drawer openings. The bead detail had to turn the corners without interruption, so the joinery called for jack miters, also known as haunched miters, to carry the profile cleanly through each transition. After careful setup at the compound miter saw, the haunches were cut into the stiles with the help of a spacer block set for precise depth.

Nathan Clark

The remaining waste was pared away with a sharp chisel, and the … Read More The remaining waste was pared away with a sharp chisel, and the rails were then cut one at a time to match.

Nathan Clark

Once everything was dry-fitted and aligned, the frame was assemb… Read More Once everything was dry-fitted and aligned, the frame was assembled with pocket screws and reinforced with wood glue.

Nathan Clark

The result is a face frame that looks delicate but is robust in … Read More The result is a face frame that looks delicate but is robust in construction, made more satisfying by the fact that the walnut was salvaged from a discarded dining-table top.

Nathan Clark

Grooves were plowed into the stiles, and the panel was rabbeted … Read More Grooves were plowed into the stiles, and the panel was rabbeted on the back so it could sit neatly in place while preserving its full 1/2-inch thickness—important, since that material would later support the drawer-slide hardware. To connect the frame-and-panel side to the face frame, loose mortise-and-tenon joinery cut with a domino machine provided both strength and alignment.

Nathan Clark

Matching mortises in the back of the face frame and the cabinet … Read More Matching mortises in the back of the face frame and the cabinet side allowed the parts to register cleanly during glue-up. Clamping blocks across the rails kept the assembly square under pressure.

Nathan Clark

The opposite side, destined to sit against a wall, was built fro… Read More The opposite side, destined to sit against a wall, was built from plywood to save cost where appearance would not matter.

Nathan Clark

With the back and bottom attached using pocket screws and glue, … Read More With the back and bottom attached using pocket screws and glue, the carcass came together ready for drawers, sanding, and finish.

Nathan Clark

With the drawer fronts in the cabinet takes shape.

Nathan Clark

Shorter pieces were placed around the sink area, intentionally l… Read More Shorter pieces were placed around the sink area, intentionally leaving gaps where the cutout would later be made. After the glue cured, the surface was flattened with a coarse-grit belt sander.

Nathan Clark

Then the top was machine-sanded through 150 grit before being cu… Read More Then the top was machine-sanded through 150 grit before being cut to rough length with a circular saw.

Nathan Clark

The exposed edge was refined with a miter plane, while the sink … Read More The exposed edge was refined with a miter plane, while the sink opening was cut with a jigsaw.

Nathan Clark

The faucet hole drilled with a spade bit.

Nathan Clark

For a vanity that would live in close contact with water, durabi… Read More For a vanity that would live in close contact with water, durability mattered as much as appearance. The chosen finish was a two-part conversion varnish, for toughness and resistance to moisture.

Nathan Clark

Spraying the finish ensured an even coat across both the cabinet… Read More Spraying the finish ensured an even coat across both the cabinet and the countertop while allowing the work to move efficiently through multiple applications. A minimum of three coats would build the protection needed for everyday use.

Nathan Clark

From there, attention shifted to the countertop, left with an ov… Read More From there, attention shifted to the countertop, left with an overhang of about 7/8 inch at the front and side. To achieve a tight fit to the walls, the slab was scribed in place—blue tape made the knife lines easier to see—then trimmed with a circular saw and fine-tuned with a hand plane. The countertop was secured from below with screws driven through corner blocks, along with a bead of silicone for added holding power and moisture protection.

Nathan Clark

The backsplash was scribed and glued to the wall with silicone, … Read More The backsplash was scribed and glued to the wall with silicone, with an additional bead at its base to create a waterproof joint. Then the final storage details were begun: large oak drawer boxes cut with a dovetail jig and smaller cherry drawers joined with hand-cut dovetails.

Nathan Clark

The larger drawers were shaped around the plumbing lines and dra… Read More The larger drawers were shaped around the plumbing lines and drain to make the most of the available space.

Nathan Clark

Copper sink basins, an oil-rubbed bronze faucet, and matching co… Read More Copper sink basins, an oil-rubbed bronze faucet, and matching copper pulls completed the piece, along with a finish that felt both functional and refined.