After doing some furniture repair for Patriots' linebacker Darius Fleming, he asked if we would do something different. Inspired by our 3D Puzzle Creatures, Darius wanted us to make mosaic out of wood to celebrate his Super Bowl victory. Not an everyday request, but we were up to the challenge! After all, it's good to flex your artistic muscles on a custom job every once in a while.

We started out by taking some choice pictures recommended by number 58 himself (and some other images to add character) and turning them into line drawings for our CNC. It took some time and patience, but it got us some awesome pieces to work with. We broke up different sections into different colors and set the CNC to make the cuts.

So many lines!

We picked different woods of different thicknesses to give the mosaic some volume. Then Dovi used his expert staining abilities to get the colors right for each piece. Every little piece had to get sanded and stained before the whole thing could be put together.

58 SPA IT TOR? That's not right...

Once everything was ready, we put the pieces of the mosaic in place. Some of the pieces were incredibly small, so we had to be extra careful to make sure everything lined up. We made a nice frame to give it a little bit of class, and let it set! Darius was thrilled with the job we did.

If he visited us at our job, can we visit him at his?

DBI Woodworks is always interested in new challenges. Recently we were asked if we could replace the cane webbing on a chair. Hopefully you can figure out what our answer was!

Replacing the cane webbing (also known as sheet cane, spline cane, or cane panels) Is a pretty straightforward task. The first step is pretty obvious- remove the damaged cane. Cane webbing is pushed into a groove with a spline glued in to hold it in place. The easiest way to to remove it is to drill holes in the spline about every 5 inches and use a steamer to weaken the glue with heat and water. Use a chisel about the size of the groove to cut out and remove the spline all the way around, and then pull the webbing out. There are special chisels you can use, but a normal one works too. Make sure to scrape out all the glue- it's a little tedious, but is very important to making sure your replacement cane stays put.

Once everything dries out. It's time to put the new webbing in. To get the webbing into the groove without breaking the fibers, you have to soak it in warm water for 1-2 hours. Once the webbing is pliable, lay it across the chair and push it into the grooves using a wedge and mallet. Cut off the excess cane using a knife or chisel so that it fits the groove perfectly. It's okay if there's a little give in the webbing- the cane will tighten up as it dries, leaving a nice even seat. Use a water soluble glue in the groove and then hammer the spline in using a block and a mallet. Once everything dries (give it 2 or three days before you sit on it to make sure everything has dried!) you are all set!

Normally you would leave the cane as-is once it's in place, but we wanted our chair to match with itself and the set it came from. Cane naturally darkens over time, so to get a good match to the original we stained the new webbing. Sanding the cane helps the the stain be absorbed. We let that dry overnight and the final result looks as good as new- or in this case, as good as the original!

If you have a cane chair the needs repair, we can do for $85 per surface. Send us an email or give us a call!