A Collaboration of Wood and Copper
Today, I am building a custom artist caddy for my friend, the talented illustrator and YouTuber Mark Campbell. Mark came up with a brilliant design to keep all his art supplies within reach. A simple spin brings a new set of colors or tools to his fingertips. Once his design was finalized, he passed it off to me, giving me free rein on material selection and the final aesthetic, particularly the patina for the copper components. This is our collaborative creation.
My first task was to construct the main rings. Concerned that drilling dozens of holes would weaken a solid wood piece, I opted for shop-made plywood. I decided to use this layered structure to my advantage by creating an accent with a beautiful piece of padauk. I milled and re-sawed the wood on the bandsaw, also preparing walnut pieces for the top and bottom layers of the plywood sandwich.
For the showpiece top, I used a stunning, highly figured piece of walnut that had been waiting in my shop for the perfect project. I carefully assembled the panels one layer at a time, using veneer tape to ensure seamless, gap-free edges. After gluing, the fastest way to remove all that tape was to send the panels through my drum sander. Once cleaned up, I squared them at the table saw, found the center, and prepared them for the CNC machine.
The plan was to use the CNC to machine the 30 holes for the copper tubes that will hold brushes and pencils. I performed test cuts to achieve the perfect snug fit for the copper pipe. I also machined a decorative collar to hide the cut edges of the pipe. However, I quickly reached the limits of my CNC; it was wide enough to start the circles but not to finish them. I had to improvise, using a router trammel to cut out the base and then using the CNC-marked centers as guides to complete the holes with a pattern bit.
Another challenge arose with the lazy susan bearing. The original one I purchased had an unattractive wobble and noise. I found a much better, near-silent replacement, but it lacked a specific attaching flange. My solution was to glue a thin piece of wingate wood to the base and route a shadow line into it, creating the illusion of a separate piece while providing enough material for a secure screw attachment.
With the woodworking complete, I moved on to the copper tubes. I started by cleaning the factory stamping off the standard plumbing pipe with a wire brush. To achieve a consistent length for all 30 tubes, I used a stop block and cut them safely on my table saw. Then came the patina process.
Wearing a respirator for safety, I etched the copper with muriatic acid, wiped off the excess, and then sprayed it with hydrogen peroxide. This chemical reaction slowly tarnished the metal. I then used a torch to heat the pieces, accentuating the colors, before quenching them in water to “freeze” the patina in place. For a more textured look, I came back with a rag dipped in acid to stipple the surface before repeating the process. Once dry, I sealed all the tubes with a spray conversion varnish.
Next, I manufactured a decorative D-ring and its clips on my smaller CNC machine. Bending the metal for the ring was a challenge—my makeshift setup was far from ideal, but I managed to form a perfect D-ring. I used a similar patina process on this copper piece to ensure it matched the tubes.
The final assembly was the most nerve-wracking part. I had to get 30 tubes seated into 30 slots in the base, which also had to align perfectly with 30 dadoes in the top ring. To help, I built a temporary base to lift the assembly and give me room to use clamps. Knowing I wouldn’t be able to take it apart once assembled, I took a risk and used slow-set epoxy in each hole to permanently lock the tubes in place.
With some careful persuasion and a few taps, everything slid into place. It was a moment of pure success. I attached the top with a screw and glued the central post I had turned on the lathe. Finally, I carefully flush-trimmed and rounded over the edges of the decorative clips.
After a final coat of varnish in the spray room, the piece was complete. This artist caddy is a testament to collaboration, problem-solving, and the beautiful marriage of wood and metal. I can’t wait for Mark to put it to use.
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