I plugged in my orbital sander and methodically worked my way down the piece, touching every surface of my first full finish carpentry project and admiring it. I had hung doors, run baseboard and casing, and trimmed out windows, but this was my first real, creative piece of finish carpentry and it was finally done.
My boss was an experienced builder by the name of Dave, who specialized in top quality, finely detailed work. I was an apprentice level carpenter and learning fine carpentry from Dave was like drinking from a firehose. Most of my prior work was as a framer, where sixteenths of an inch were given minor consideration, and even then, only when it was convenient. With Dave, we went to 32nds, and his favorite dimension, the ‘fuzz’: “take a fuzz more off of that stick please,” or “ cut this at 64 ½ inches minus just a fuzz”. Every complicated cut or drilling needed a jig, which then had to be designed, built, and tested. If the jig was built wrong, then the subsequent cut or drilling would be wrong, and would damage or destroy our materials. Those materials we worked with were select pieces of cherry, mahogany, walnut, and maple; our cheap woods were poplar and birch, and high-quality veneer woods. It was fun to build things with these beautiful materials, but there was an added level of stress, as the dollar value attached to each mistake was far greater than when I was working with framing material.
I had spent a lot of time making mistakes. One of the most valuable skills of an experienced craftsman is the knowledge of when you can move fast and free, and when you must slow down and give extra attention. As a rookie, I had a tendency to get these all backwards. There were plenty of days when Dave would step from his office into the shop and hassle me (in a good-natured way) for taking way too long to measure and cut sticks: “you have to cut 20 of them, so set yourself up a saw stop and wham, bam!”. Then there were just as many days where he would run into the shop and stop me just in time from doing something aggressively foolish: once I felt that since was taking up way too long cutting and fitting a cherry wood bench, I would make that lost time up fast by doing my finish sand with the belt sander. A whole lot more time would have been needed to finish (or rebuild) that bench had Dave not caught me just before my finger found the trigger.
But that was months ago, and this was the project Dave had given me to try my hand without supervision (beyond some layout, some dimensions, and some initial suggestions on how to not waste my material). The project was a set of stairs leading up to a small attic apartment in a garage workshop, and the plan was to finish grade plywood to form a series of square cubbies underneath the body of the staircase. Easily accessible from the side, the cubbies would be perfect for garage storage, and with careful planning, we were able to use whole lumber, so each piece of the staircase locked against the others at every intersection without a break, keeping the cubbies square and the stairs strong, all while giving the whole assembly a completely seamless look.
It was not the most complex job we had done, but it required some careful math and some very precise cutting, so it was plenty for me to handle. It took me two days working solo in the shop to run the math and detail out the design plan; cut mockup pieces to dial in my joints; then measure, double check, triple check, and finally cut all my pieces. It took another day to haul all my cut lumber out to the site; hoping desperately I had cut it all properly; and begin assembling the stairs, carefully stacking and gluing each piece, enjoying the thrill of affirmation every time the wood clicked home with a gentle tap of the rubber mallet, establishing another row of neat and clean cubbies.
I wrapped up the assembly late in that third day and set about the final sanding to soften all the edges, remove splinters, and give the whole assembly a silky feel suitable to be painted or just left raw. It had been three days of blinking the ultra-fine saw dust from my eyes, three days of picking maple-colored boogers from my nose on the drive home, and three days of razor-sharp focus with no mental brakes - even my dreams had table saws and plywood in them. But here I was wrapping up the finishing touches on the first piece that I felt real ownership over. This was my project, and I did it right.
Dave wandered into the garage after wrapping up a conversation with the owner and stepped back to survey my finished handiwork. I was about done so I shut off the sander and stepped back to join him, ready for a bit of rare praise. Like a lot of guys in construction, Dave doesn’t just give out compliments; they have to be earned. Before he said anything, he walked up and down the stairs, scanned along the joints, looking for gaps and errors, and thumped the wood here and there looking for flaws. Apparently satisfied, he stepped back and took in the overall piece one last time.
“Why are the steps sloped?”
My heart jumped, and I looked hard at the steps. “What do you mean?” I asked. But as I looked ever so closely at the steps, I could barely perceive that each tread of the staircase had a very slight gradient down to the nose of the stair.
Dave didn’t answer. He didn’t have to. I already had my tape measure out and was verifying. Sure enough, each stair was 1/32 shorter at the nose than it was at the heel. I had mis-cut each riser piece by just that much and while it was so little as to be imperceptible to me at first (and probably to most untrained eyes), now I could not look at the stairs without feeling like they were hopelessly cascading downhill. They had gone from textbook geometrical squares to an Escher painting with one simple question from Dave. It made me dizzy to look at and I was horrified.
“On no! What do we do?”
Dave looked at me steadily, taking in the sweaty, dust covered clothes and hair, the Band-Aids on my fingers where I’d pinched and smashed them, and the mortified expression on my face.
“Eh, it’s for drainage. Looks great.”
The stairs were in the middle of a fully covered garage, and there was no water even plumbed to the building.