This project came about through a chance meeting at the Old Hilliardfest Art & Street Fair. The homeowner wanted to bring the feeling of her recently sold farmhouse into her new house. She had done her homework and knew exactly what she wanted. 3/4" solid wide plank white oak, hand cut live edges, completely prefinished off-site culminating with multiple coats of OSMO oil, and finally nailed down (no glue). I immediately felt a connection and knew this was going to be a wonderful process and a beautiful end product.
The process of prefinishing the hardwood off-site proved to be the most challenging and rewarding step of the project. Each board went through 13 dedicated stations prior to being loaded onto the trailer for delivery. Starting with unfinished white oak from a nationally recognized top tier mill, Sheoga, we began to age the wood with hand tools. Wire brushes, a spokeshave, a draw knife, and a scraper. Each adding subtle characteristics to the boards. The boards were blackened with a vinegar/steel wool solution prior to being sanded. Each board received multiple coats of OSMO oil followed by machine buffing. The boards were air dried on drying racks to cure prior to installation.
I had never heard of OSMO oil until this project. It turned out to be a great product. It's a natural, low VOC oil/wax finish that penetrates into the wood and protects from within as opposed to building a film on top of the wood. The result is a very deep and rich color while not creating a barrier between yourself and the wood. Hand applying the OSMO at waist level in good lighting allowed us to ensure proper coverage.
Believe it or not, mixing steel wool and vinegar together and allowing to sit for different amounts of time will turn certain species of wood a dark color when applied. The solution interacts with the tannin content of the wood. White oak has a high tannin content, so the effect is pretty dramatic. Once dried, the solution was sanded off the surface yet remained in the recesses.
The installation went very smooth thanks in part to Sheoga's exceptional milling as well as the wide width and long lengths. Notice the cut nails in the picture. Similar to the Forest to Floor project, the entire floor was face nailed due the wide width. A pilot hole was drilled for each nail prior to being hand driven. There are thousands of cut nails in the floor and in conjunction with the cleats that were blind nailed, this floor is crazy strong.
Thompson Hawken blackpowder build kit that I inherited from my grandfather. This project took a few weeks to complete but it looks amazing!
This was made out of a log that was being used as a support post in our old barn. The base is the bottom half of a fire tool holder.
The bookcase was made for my niece. I used old stair treads and risers from a house in Victorian Village along with old 2x4's from a house in Harrison Village. It's finished with Rubio Monocoat 0% VOC oil.
The table was made for my friend Jordan. We used a skid and spliced in some hardwood from other skids. It's finished with many coats of spar urethane.
This was a tremendous project and such a positive impact on me as a hardwood professional. The idea was to create a floor with a traditional feeling. To achieve the traditional feeling we used traditional techniques. Hard maple trees from Thronville, Ohio were cut and processed with a bandsaw mill. The boards were taken to Holmes County, Ohio where they were turned into tongue and groove flooring measuring 8", 7", 6", and 5". The flooring was installed by blind nailing with the pneumatic nailer as well as replica 18th century cut nails installed by hand (over 1,000!).
The flooring was installed in completely random widths. There is no discernible pattern between the 8", 7", 6", and 5" boards. The cut nails were driven into the home's floor joists providing a tremendous amount of holding power. The floor was finished with a linseed oil and wax which added depth and helped to define the bandsaw marks. The color was selected to match existing wood work in the home. The floor completely transformed the home.
The maple was taken from the farm in Thornville to the lumber mill in Holmes County. The 1" thick boards were planed down to 3/4", squared, ripped to the appropriate width, and tongue and grooved. The mill did a great job.
The cut nails add such a neat touch. They were acquired through Tremont Nail Company in Mansfield, Massachusetts. Tremont operates out of the same nail manufacturing mill they first opened in 1819 and still uses some of the same equipment from the mid 1800's. These particular cut nails are called boat nails. The middle of the nail is wider than the top and bottom.
The combination of the aesthetic attributes of the floor along with the knowledge of the floor's origins 50 miles away, merge to create a truly unique and traditional floor. To read the article I wrote for Hardwood Floors Magazine follow the link below:
This project evolved around the notion of a "worry-free floor." The idea was to create a hardwood floor that could withstand the abuse of everyday family life while minimizing the visual effect of that abuse. Also, the floor needed to be able to handle the effects of open windows a large portion of the year in Ohio. The "worry-free" effect was achieved through a combination of 3/4" engineered hickory, hand scraping, and a linseed oil wax finish.
Plant based and volatile organic compound (VOC) free, this finish combination is driven into the wood using a buffing machine. The high RPMs in conjunction with the weight of the machine simultaneously heat up and drive the finish into the wood fibers. The result is a finished product with depth that brings out the natural color of the wood along with the grain. In addition to the organic look and natural sheen, normal wear-and-tear do not produce the unsightly white scratch marks commonly associated with a factory finished floor. Any areas identified as needing repair can be locally touched up with a few drops of oil.
The hickory is an engineered product meaning that it is not solid hickory. Each board is 3/4" thick with the wear layer (top) being hickory. The wear layer on the hickory for this project is the thickest on the market. The core is comprised of 11 layer baltic birch cross-grained plywood, which is also the best on the market. The benefit of engineered hardwood flooring is that it is very dimensionally stable. It resists the urge to expand and contract due to humidity swings much more than solid hardwood (especially in wider widths). This engineered hickory is also Forest Stewardship Council (FSC) certified ensuring that is came from responsibly managed forests.
First, the edges of the hickory boards were eased by hand using a sanding block. Each board was then softened with a damp sponge and hand scraped using a two stripe pattern. The boards were then hand sanded. All of that was done prior to installation. After installation the entire floor was hand sanded once again. The hand scraping adds character and texture to the floor while also serving as camouflage for future wear-and-tear.
Prior to the advent of drum sanders for flooring use, hardwood floors were scraped flat using a hand scraper. It's very challenging work, however, the look and feel of the finished floor is truly authentic. Walking on the floor barefoot will make you realize that this is the floor you were meant to walk on. You can feel the connection to the wood and the craftsmanship.
To view videos of the project, visit our Facebook page https://www.facebook.com/patrickflooring/
These stairs were custom designed and built for a client in Victorian Village. They lead from the second floor up to the third floor loft. We wanted to expose as much of the brick wall as possible while building a set of stairs that appeared as though they were original to the house. They were made out of pine to match the floor and finished in a Rubio Monocoat 0% VOC oil.
This turned out to be a really neat varying width hickory floor in German Village. The widths are 2 1/4", 3 1/4", 5" and they combine in a non sequential order to create a unique floor. The open stair rail gave us an opportunity to incorporate a subtle design element.
Jake takes some pretty cool pictures
This is an original staircase in German Village getting sanded down with the Festool. The staircase leads from the first floor to the second floor. We wanted to blend the blonde hardwood on the first floor with the dark hardwood on the second floor. We decided to sand off the the old finish, but not deep enough to remove the character marks from 100 years of use. We actually highlighted the character marks with a dark stain before applying multiple coats of a water based polyurethane. We also gave the risers a facelift.
We installed 5" bamboo in this dentist office. We also made our own baseboard for this project.
This was a Bob Webb built house in Muirfield Village right across from the golf course. This house is the best built house that I've worked on, which makes my job easier. We installed over 1,000 square feet of 2 1/4" maple. We installed a neat picture frame design around the fireplace too.
The pieces in this collection are designed to establish a distinctive atmosphere to a living space. In addition to that atmosphere is the tactile experience of the floor against your feet. Whether it's smooth, textured, or something in between, each of these pieces can be tailored to suit any design vision.
An old 4x4 and 2x4 from my family's barn was sliced into 3/4" thick pieces. The pieces are glued into place and finished with three coats of tung oil. The pattern options are endless and quite unique.
Hand scraped with an emphasis on chatter marks, this character hickory is hand sanded two times before being finished with a linseed oil and wax.
Lightly hand scraped with hand eased edges, this character hickory is hand sanded two times before being finished with a linseed oil and wax.
Similar to the elegant oak, this hickory is subjected to the vinegar solution. The result is less dramatic than the white oak due to the lower tannin content of hickory. The hickory is finished with three coats of polyurethane.
A light hand scrape, subtle eased edges, and two hand sandings prior to the application of a vinegar solution that reacts with the tannin in the white oak. The reaction turns the oak very dark while still allowing for variation and grain bleed through. The oak is finished with three coats of polyurethane.
Wide plank oak boards are distressed as well as edge scraped before applying a vinegar solution. The boards are then hand scraped removing the effects of the solution on all but the recessed distressed marks. After two hand sandings the oak is finished with shellac and wax.
Hand scraping walnut is like a nice dream. It lends the craftsman the ability to take liberties with the depth of the scrape. This is a patterned scrape at the long joints and one down the middle of the board. The walnut is finished with three coats of tung oil.
This is the original sample board from the forest to floor project. Wide varying with planks, band saw marks, hand eased edges, hand driven steel cut nails, and lightly sanded with a Trio. This maple was finished with a linseed oil and wax.
We installed over 1,000 square feet of 5" acacia over the entire first floor of this house. The picture framed fireplace turned out really good.
It's a challenge finding a use for remnant hardwood flooring. I have a deep seated disdain to throw anything of potential use away. We have created a few useful items entirely out of remnant hardwood flooring. The items are available for purchase in the Products section.