An essential part of the woodwork experience is fixing wood defects, gaps and mistakes. Defects might include knots, cracks, lumber inconsistencies, bowing and twisting. Woodwork mistakes include not cutting a material properly, mishandling a material, or machining holes in the wrong positions.
Understanding how to fill gaps, fix mistakes and wood defects will save a lot of time and money for any woodworker. Additionally, having these skills will improve the quality of a project and the efficiency in which it is manufactured.
Wood defects
Woodworking defects come from a variety of sources. Understanding the causes and manufacturing solutions is important to best utilize materials and reduce waste. Wood defects will either be naturally occurring or the results of poor seasoning. Let’s take a look at practices that will assist you when working with wood defects.
Natural defects
The most efficient way to avoid problems with natural wood defects is to inspect and select the timber that you purchase. This minimizes additional rectification time caused from natural defects in timber. As this isn’t always a viable option, there are some workarounds that can be undertaken to limit the amount of inevitable waste.
Loose knots
Loose knots can be filled with epoxy resin. This solution can be visually appealing and even sought after, although it’s a complex and expensive practice that requires preparation and a setting time.
Large knots
Large knots can be cut out and removed from the timber. Replace the large knots with a wooden plug, or cover with a decorative inlay. This practice can be matched with the same material, finding and using a section with similar grain and colour properties. Again, this requires time and additional material to do productively.
Small cracks
Small timber cracks can be repaired with wood resign or wood putty. This is a timely practice but can strengthen the timber in and around the crack.
Waney edges (live edges)
Waney edges can be trimmed off of a length of timber if not required. Additionally, they are commonly used as a feature in projects. Sanding and finishing them can showcase the defect as visually appealing.
Seasoning defects
Seasoning defects can occur when the seasoning process has not properly taken place. These defects display themselves in different forms including warping, bowing, twisting, and even collapsing.
Fixing bowing
Bowing in timber occurs when there is a moisture imbalance in its structure. The following methods may be used to reduce these seasoning defects in timber:
- Lightly mist the timber with water and use weight to gradually straighten the timber; this should be completed gradually and could possibly rehydrate timber and reshape it
- Steam the timber with a steam iron in heat intervals and weigh the timber flat; this additionally can rehydrate a board and reshape the timber
- Mechanically correct the timber if possible by machining a smaller board internal to a larger board; it should be recognised that there is already a moisture inconsistency within the timber
Under cured manufactured board
When it comes to manufactured boards, these are usually manufactured, strapped together and cured for at least 7 days. This holds a sheet in the correct shape and reduces seasoning defects while the setting process is taking place.
You can usually tell if the curing process for manufactured boards hasn’t been given the required timeframe as a sheet will hold its warmth and this can be felt by hand in the centre of the sheet. If this is found, restrap the sheets and allow them to rest in a dry location for an additional few days. It is recommended to contact the manufacturer/supplier and notify them of the curing error.
Woodwork mistakes
Woodworking mistakes are a common problem that everyone faces, both professionals and DIY’ers alike. There are many ways to avoid woodworking mistakes before they happen, or to make the best of a bad job!
Proper storage of materials
Correctly storing materials is very important in preventing seasoning defects. Materials should always be stored in a dry and flat location, not placing any strains upon the timber. It is good practice to always store timber off the ground, simple gluts or racks work well.
Filling incorrectly bored holes
Drilling holes in the wrong location is easy to do. Depending on where it is situated and if it is visible, filling a hole and re-boring may be an option. The following methods can be used to fill holes:
Builders putty
Builders putty, sometimes known as builders fill or builders bog, usually comes with two separate components that need to be mixed together. This hardens in a short period of time and creates a solid filling that can be drilled with similar properties to solid timber.
Timber plug
Filling holes with a timber plug is a common solution for woodworkers. Find a spare piece of timber, cut a plug to fill the hole, glue it into position and sand it smooth.
Super glue and saw dust
When mixing superglue and saw dust, an exothermic reaction takes place and results in a solid fill that can be used in timber. Most fine dusts can be used for this practice, although caution should be taken as exothermic reactions can be dangerous if not done properly and in the proper environment. See an example here.
Prepare timber for cutting
When cutting timber a good woodworker will plan cutting patterns around the material that they are using. Considerations when preparing to cut timber include:
Choosing what face to cut
Commonly, panel saws should cut material face up so that the face won’t scratch on any debris or woodchips that get under the material. When using circular saws, cutting a melamine faced board upside down will minimize chipping from the reversed blade.
Taping cuts
Taping some solid species of solid timber will prevent the grain from flaking, tearing, or splintering from the cut.
Selective cutting
Where possible, choose the best material to cut. Avoid incorporating natural defects in components and you will avoid problems later in the manufacturing process.
Boost workshop production
Filling gaps, mistakes and wood defects are skills that all woodworkers should become familiar with. Having this knowledge will support manufacturers in creating the best quality products while also minimizing unnecessary costs.
Wood Designer offers professional stair and furniture design software, our technical staff are also available to provide support and expert advice.
If you have any questions or would like to see how we can help your workshop grow, contact us today.
