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The start of a massive bar like the Alabama tavern is a truckload of rough sawn material. It is first thicknessed to various purposes, and parts begin to appear. Here some first milled parts are inspected for the mortice-and-tenon fit.
Below is a stack of parts coming off the shapers,and some 90-degree corner panels. To obtain a smooth satin finish, open-pore woods like red oak must be paste-filled thoroughly, then sanded before staining. Before glue-up, those areas which could be “masked” by the glue are pre-stained.
The footprint is laid out on the shop floor, and the foundation components are secured;
then sub-assemblies are tested for fit.
pre-assembly is done in shop, of the entire bar, to assure on-site installation holds no surprises.
Three of us installed the Aabama Tavern in 3 days. Overall views give some idea of the scope.
A couple of details are below; the, canopy corner, the corner below, and the Silestone top.