As you can see from our site, mirrors have become the focal point of our design. The existing mirror industry is limited to a few basic shapes and the majority are factory made from overseas. This allows us to create a unique space in the industry as we can continue to expand on our designs and ideas you cannot find anywhere else.
First things first: buy some wood. We are lucky to reside in a plentiful region for woodworkers. Slabs, boards, and sheet goods are not hard to find in Western PA. For mirrors we buy local ash and maple. The more finishing gets done at the mill, the more the price goes up. For this reason we and many other woodworkers rely on our tools to finish the wood to completion. We run all of our boards through the planer to get the desired thickness. Once planed, the boards go through the table saw to create our desired stock.
To make a round mirror we must first make an octagon. We miter cut the strips into 8 pieces of equal lengths, depending on the size of the mirror we are making. Once the 8 pieces are glued and joined together, we are ready to take the structure over to the CNC machine.
All of our round mirrors go through the CNC machine. The process is smooth now, but CNC projects always take a bit of time and patience to get perfect. Router speed, bit choice, centering the wood, are a few variables that go into creating a perfect circle frame from the CNC machine. At this point, all sizes of round mirrors have programs and files ready, so it is a matter of securing the wood to the CNC and hitting go.
We now have a rough outline of the final structure. All that is left to do is sand, stain, and protect the mirrors. Sanding can be quite a drag, but finishing mirrors is always gratifying. It never gets old prepping final products for customer’s homes. We coat all mirrors with Odie’s Wood Butter, an excellent oil/wax mixture that protects wood from the trials of time and use.
Now that we have a fully finished frame, it is time to cut glass, attach hardware and get the product out the door. Al cuts all of our glass, some freehand, some by using more intense instruments.
Time to ship this beauty off to a loving home!