They say nothing can prepare you for the role of a parent…especially a parent during an unexpected pandemic lockdown with a teenager. That’s what Shane Bergman, his wife Kandis and their daughter Layla (along with millions of other parents) experienced last March.

“They shut down the schools and we were all at home. But then Layla finished all her schoolwork within a few weeks so she had nothing to do,” Shane says.

They could have panicked and signed their kids up for a million additional online courses, but that’s not what happened with the Bergmans.

Necessity is the mother of invention…especially during lockdown

Since his daughter completed the school year early, Shane had to quickly think of a project to keep her occupied that would also help bring some normalcy and fun into their lives. He kept in mind that Layla wants to be an engineer.

“My wife Kandis had always wanted a patio set, so I asked her if she wanted us to build one. So we all got in on it together. I got all the wood, Layla helped with the measurements, joining and puttying, and Kandis painted it. So we made a little assembly line.” 

They all enjoyed the work, and Shane felt good about using lumber produced in east Texas — especially since part of his job is to sell New England Forestry timber to lumber mills in that area. 

After they completed the set, Kandis posted a picture on Facebook. Little did she know that photo would launch their pandemic family woodworking business.

“She got so many likes from the photo that she asked if anyone would be interested in buying one…we got 4 order requests within the first 24 hours.”

Lack of Experience Didn’t Stop The Bergmans from Building and Selling Their Furniture

Shane and his family which, up until lockdown, had very little experience building, went into business head first.

“My Dad was a welder and then he went back to school to be an Elementary ed teacher, so he had a lot of blueprint skills and I’d help him on projects growing up,” Shane says. “But it’s different when you’re actually there measuring and making the cuts. The year before, Layla and I built a deer stand and put a tin roof on it and stained it. That was our first go and we haven’t looked back.”

YouTube videos, some refresher geometry tutorials and hands-on work provided the bulk of the Bergman family woodworking education. 

“My daughter wants to be an engineer so she’d do all the measurements with me and she kept a little cheat sheet up in the garage. The hardest things for me were the angles, because I want to know exactly how you calculate that, so I refreshed my geometry and everything to get that right.”

The orders poured in throughout lockdown, which made for many busy nights in the garage.

“We started in March and did that for literally a month straight after work Monday through Friday. It was to the point where my wrists and fingers were killing me! But it was fun and we’ve had a few people reach out ever since. If I would have known what I know now about the rush on wood, I would have bought a big flat of 2X4s in the beginning from our local sawmills. But I’d have to say it was fun just hanging out and listening to music with Kandis and Layla.”

How did he keep his daughter engaged with the hard work and long nights?

“I’ll be honest with you, she was always saying she needed to make money so I told her I’d pay her a commission and she went for it and learned some responsibility too.”

His Favorite Woodworking Piece To Date

Although patio sets were their most popular product, Shane’s favorite piece he’s built is this two-seater burnt bench pictured below.

Here’s how he achieved the finish using fire:

“When you use southern yellow pine, you’ve got naturally lighter and darker colors in the wood grain. So, you take a little blue propane torch, light it and keep it 3-4 inches away from the wood and it just accents it like a zebra print. Then we add a clear coat.” 

The technique takes patience, but it’s not hard to learn.

“Just don’t do what one of my buddies did. He used lighter fluid to speed up the process. It worked, but I wouldn’t recommend it! I spent about an hour and a half on just that bench to get it right, and once you see the end result it’s pretty cool. That board had really good characteristics.” 

He learned the technique on YouTube.

Shane’s Advice For Woodworker Newbies: Make The Time and Just Do It

Obviously Shane doesn’t shy away from learning something new on the fly. But his perspective serves as good advice for aspiring woodworkers who are on the fence about how and when to get started:

“I just do it. I’m one of those people who believes you can’t get time back, and some things you’ve got to say no to and some things you say yes to.

“Anything you want to do now, whether it’s mechanics, fishing or anything, you can find a way to kind of get your feet wet and learn. After you research it you’ll find it’s not that hard. I’d just type in ‘wooden patio sofa’ and see what videos came up. For woodworking though, Home Depot has a lot of stuff online and they’ll give you a whole list of exactly what you need, the lengths, etc. The cuts are the most intimidating, especially if you’re going to cut on an angle. Also, I wouldn’t jump in and buy the most expensive tools to start with. I’d go to Harbour Freight to start out with a cheaper tool, and that way you can find out if you like it before spending more.”

As we’ve all learned over the last year and half, life can throw us some unpredictable curve balls. And something like a pandemic lockdown can create serious challenges for families. Yet, the Bergmans’ story serves as a reminder that life is truly what we make of it. 

In their case, a lockdown brought them closer together as a family, taught Layla some basics about managing money and starting a business and provided the opportunity for them to forge a new hobby in woodworking. Not a bad way to spend a few months stuck at home.

Congrats to Shane and his family on their pandemic side-hustle and beautiful patio sets!

The post The Woodworkers of Rayonier: Shane Bergman appeared first on New England Forestry Stories.

New Zealand has been one of the most successful countries in keeping coronavirus at bay. But that doesn’t mean its citizens got to skip lockdowns. On the contrary, their lockdown periods were stricter and longer than here in the United States. That gave Northland Forest Manager Sam Middlemass some extra time—and extra challenges—in creating his DIY wood projects.

The Obsession Started In Primary School

It’s not every child who has the opportunity to take woodworking in school these days. However, in New Zealand it was offered as part of Sam’s primary school curriculum. And from that simple grade school instruction, a full-blown passion developed.

“After school, I worked as a fencing contractor like my father did for the bulk of my childhood, until I was employed by Rayonier,” says Sam, who’s based in Whangarei. “So my work has always involved wood in one way or another.”

Sam is humble in describing his approach to woodworking: “I focus on prominently timber and reasonably rough construction. Everything I’ve made is pretty much all for outdoor application and doesn’t require a great degree of craftsmanship. To give you an idea, one of my favorite tools is the chainsaw!”

The Special Challenge Of Procuring Wood On A Small Island During A Pandemic

People from around the world have different opinions about the United States in general. However, if there’s one thing they all agree on, it’s that we are spoiled in terms of the variety and availability of consumer products. And according to Sam, wood is no exception. 

“One thing I found very interesting with this DIY contest was seeing what types of pieces were made in the States. I’m always amazed at how many types of wood working tools and materials are available there. Here in New Zealand we typically have locally-grown pines, so to get black woods or eucalyptus, etc., you usually have to go to a specialty store.”

You can view some of the winning U.S.-based projects in our other Woodworkers of New England Forestry articles.

Sam added procuring any type of wood for projects during lockdowns was even more of a challenge due to an unprecedented run on supplies.

“Luckily, I have my wood pile under the house, so I had to be resourceful and made due with what I had on hand.”

Like many houses in New Zealand and other coastal areas, Sam’s is elevated, which provides the perfect spot to store wood.

The Cape Cod Chair That Became A Picnic Table Bench

One of Sam’s favorite projects was a beautiful picnic table bench combination which he made at the request of his wife.

“It came about because my wife mentioned that she wanted a version of a Cape Cod chair. I had no idea what that was, so I looked it up and thought it was rather ugly! So, I sort of figured out how to redesign it and that’s how we got the picnic table bench. I started it one afternoon and finished it the next morning. If I made another one now, I’d probably bang it out in an afternoon.

“I put the table together pretty quickly but it actually does work and I’m quite proud of that. And the satisfaction you can get knowing that it was done by just looking at a picture! I like to look at something and make it better and customized. I never make something exactly from someone else’s design.”

During New Zealand lockdowns, Sam and his wife took advantage of the time to do some more extensive woodworking projects, including changing out their back porch for a more functional design.

His Favorite Project And Favorite Woodworking Tools

Insofar as his favorite project ever, Sam says: “That would have to be when I extended the decking on our house and made it much more useful and less narrow. I expanded the width and did away with the kink in the decking. That’s probably the piece that was most useful.”

Like his craft, Sam keeps his woodshop simple. Set up in his garage, he keeps a skill saw, an angle grinder, a jigsaw and other basic tools. 

“My favorite DIY tool at the moment is an angle grinder with a sanding disc attachment. This is used to make joints fit neatly if they don’t, round edges and create shapes in softer wood types, such as finishing off chainsaw-carved bowls or platters. It removes wood much faster than an electric sander and I’d hate to have to do what it does by hand.”

Like our other contestants, he emphasized that you don’t need a lot of fancy expensive equipment or tools to create functional wooden pieces.

Sam’s advice for aspiring woodworkers: start simple and seek inspiration

Sam’s no-frills designs speak to his core beliefs about woodworking: it should be simple, fun and rustic. 

“Crikey, my only advice would be to just give it a go. It’s not hard. Particularly these days with screwing things together, we’ve got the power tools for it—so get into it. Start rustic first and work your way up to the higher-level skill stuff.

“I thought this competition was fantastic because of the fact you get to see so many quirky projects that other people have made. It inspires you to expand your horizons when you see somebody else’s creations.”

We can’t wait to see what Sam comes up with next!

The post The Woodworkers of Rayonier: New Zealand’s Sam Middlemass appeared first on New England Forestry Stories.

When we launched our Wooden DIY Projects Contest for employees during the 2020 pandemic lockdowns, we had no idea just how talented our New England Forestry employees were at woodworking.

From hand-carved tables to cider presses, wooden coolers, workout benches and everything in between, the task of choosing a winner from such a creative and resourceful bunch was a tall order.

However, one project stood out as the overall fan favorite: Traditional East Greenland Style Kayaks built by Resource Land Manager Neris Biciunas. 

We caught up with Neris, who’s based in Forks, Washington, to get the story behind what goes into crafting these buoyant beauties, and learn more about his journey to woodworking.

Building kayaks began as a family affair

Whilst admiring these kayaks, you’d never believe they were hand-constructed in a self-taught hobbyist’s garage over the course of a few weekends. But that’s exactly how they were made.

“When people look at the kayak I made, they think: That’s epic and must have taken you forever! But the truth is, most of the instructions came from a book. The rest came from the wisdom of the internet, and I simply took it one piece at a time,” Neris says.

He started woodworking as a hobby several years ago. As soon as he had a place to work and his daughters were ready to start playing in the water, he began building wooden kayaks.

“I could have followed the path of kayaking as an individual sport, but I made a deliberate choice to include my family. And it’s nearly impossible to buy a kayak for a small person no matter how much money you have. So that pointed me toward building something, because I can build a scaled-down kayak for a small person.”

Neris’s daughters, now 17 and 20, learned to kayak from a young age.

“Sea kayaking is pretty easy because you don’t need rapids or a three week expedition, and it gave them a chance to learn about doing it safely from an early age. When they outgrew their kayaks, we could pass them on to other growing families.”

The history of wooden kayaks and their traditional craftsmanship

The only thing more enchanting than looking at these kayaks is learning about their history…which Neris tells with enthusiasm.

“Kayaks originated as a very efficient hunting vehicle for people in arctic areas—and they had to be efficient or they’d go hungry. What’s really interesting is they had very few resources to build with…they didn’t even have trees up there! So the first question is: where do you get lumber? They’d use driftwood. They also didn’t have nails, bolts, glues, or high-tech materials so a large piece of driftwood was split into many smaller pieces for the structure, the occasional bit of bone material for a joint, animal sinew [tendons] for lashing parts together and seal hides for the outer coating. And that’s why many people call this style ‘skin on frame.’”

Applying traditional techniques to contemporary kayaks

For his modern kayaks, Neris blends traditional building techniques with contemporary materials. Either nylon or polyester fabric with a certain type of varnish or paint mimics the function of a seal skin.

“For my daughters, I used a canvas material for a skin because I can seal it with an exterior house paint. And I used nylon for the bigger kayaks. The joinery is a combination of things. Dowels or mortise and tenon make most connections. Many parts are lashed together. The ‘skin’ also contributes to strengthening the whole craft. ”

For sourcing the wood (Douglas-fir, Western Red Cedar, Port Orford Cedar, Pacific Yew, and Vine Maple), Neris has found certain pieces at the local saw mill, his woodpile and the hardware store. He sources specialty pieces, like curved wood, directly from the woods (including Raynioner slash piles).

The “why” behind the hobby

Everyone has different reasons for pursuing woodworking. For Neris, it’s mostly about the opportunity to learn something new.

“It is also very relaxing to whittle away at something. Part of that learning process is studying the idea and looking at alternatives and thinking about how I can accomplish this with what I have for materials and skills. I like to think of it as learning and understanding, and by practicing I increase my level of understanding.”

Some of his other favorite projects include a cider press, the bread kneading trough shown above, a wood-based workout station, and skim boards.

Neris gave an example of that deepened understanding and experimentation when sharing about his favorite piece he ever made, a kayak for his wife. In need of a 20 inch piece of wood to manipulate into a U-shape, something that’s typically done with a large steamer, Neris used a piece of vine maple which he heated in the microwave to achieve the same result.

“I took it out of the microwave and it bent like a wet noodle! You can’t build furniture with a microwave, but it worked great for a kayak. And that kind of goes back to looking at the process and thinking, ‘How else can I do this with what I have?’”

This spirit of working with what you have seemed to be universal among all the top New England Forestry Woodworkers. The bottom line: you don’t need expensive equipment or a lot of space to create amazing wooden art.

Neris’s advice for aspiring woodworkers: pick a target and do it

When asked what advice he would give aspiring woodworkers, he replied: 

“Pick a target and do it. Start appropriately for your skill level and build on your experiences. Woodworking is very friendly toward little increments, little steps at a time, little pieces at a time.”

He also recommends Instructables.com, which features plans for wooden kayaks, along with many other beginner, intermediate and advanced-level projects.

On behalf of the entire New England Forestry team, congratulations Neris! He won the overall fan favorite award and the large outdoor category.

You can read more of our DIY stories featuring talented woodworkers here.

The post The Woodworkers of Rayonier: Neris Biciunas appeared first on New England Forestry Stories.

Robert Hall’s favorite DIY wood projects combine dark woods like cherry with layers of navy, sea blue and white epoxy. It’s not only beautiful but could also serve as an artistic symbol of his woodworking roots.

The son of a minister who also was one of the first Habitat for Humanity employees, Robert has been honing his craft since his childhood days spent in the mountains of Western North Carolina. Now a resident of Florida, his projects seem to reflect the unique characteristics of the two regions, forest and sea.

It all began in Grandpa’s workshop

“My grandfather was the woodworker and he really enjoyed doing it. He worked for Oland in Brevard, North Carolina, in the pulp and paper industry, so that was neat to do the same when I came to Rayonier.”

Among his grandfather’s many woodworking projects included crafting all the gavels used by the town’s judges.

“That’s where I got my love of woodworking, from going down to my grandfather’s basement. It was good male bonding time if you will, with my grandfather and my father.”

As fate would have it, Robert wound up inheriting a 40+ year-old cut of cherry wood found in his grandfather’s attic after he died, which he used to create a wood/epoxy river desk (pictured below). 

Robert’s family history as Habitat for Humanity trailblazers

Robert’s building skills were enhanced by his family’s involvement in the early days of Habitat for Humanity. 

“I would say my dad was the glue that held Habitat together for a while. He was a Baptist minister who took a pay cut to work for the non-profit and acted as a calming force for the early leadership, reminding them that what they were doing was the Lord’s work and we needed to make this happen. So I did a lot of work in the photography lab but also working on the houses and that kind of stuff.”

The story behind Robert’s prize-winning charcuterie boards

Robert made charcuterie boards out of cherry wood procured from unwanted fallen trees. 

“My ex-wife’s father had a cherry tree fall on his property from a neighbor’s. It was a vacant lot and a bad storm had come through, so he called the neighbor up and offered to take care of it, and the neighbor agreed he could have the wood. So we cut it up and had it milled. I took the majority of it.”

Two layers of epoxy were used to create an ocean effect on the wood. Each board is unique, with the cracks and knots giving them character. They were finished with a food safe oil and a coat of wax.

How Hand Tools Give This Craftsman His Edge

One thing that intimidates many aspiring woodworkers is the thought of investing in expensive power tools. However, for Robert it’s the hand tools he’s come to enjoy most.

“I use machines, but I do mostly hand tool work now. And part of the reason is to slow me down and to really feel the wood and know what’s going on. You get more connected to the piece than if you were just running it through machines. 

“Even the act of sharpening the blade to prepare for the cutting of the wood is part of that whole process of sharpening my edge—not just the tool’s edge, my edge too. Really getting in there and making sure everything is just right. That ‘zing’ you feel when you run the tool over the wood…it’s so wonderful.”

Woodworking offers Robert relaxation, creative space, and the opportunity to share his love of the craft

When asked about the biggest benefits he gets from woodworking, his response was three-fold:

“The relaxation I get from it is obviously great. But I think for me, just being able to create something with my hands is just so rewarding. And I really love when other people take it, and I know they are using it in their life. I don’t keep a lot of pieces I make, I like to give them away.”

To illustrate the point, Robert described a piece he hand-made for a friend, which is one of his favorite projects to date. 

“Like the table with the crosses on it (pictured below). There was so much that went into building that piece and it was literally done all by hand with no power tools. Everything was cut with a hand tool: embedding the crosses, the dovetails on the drawers, the pull for the handle for the drawer, absolutely everything was done by hand. And it is still in a good friend’s home, and just to know it’s in her house and she gets joy from it is so rewarding to me.”

Robert’s Advice for Aspiring Woodworkers: Keep it Simple and Learn from Others

On tools: “I have accumulated a lot of tools over the years but I still come back to just a handful I use most of the time. For me, it would be a # 4 1/2 plane, a good saw, and most importantly a good bench and good vice, and that’s really all you need to get started.”

Robert also suggests using other people’s creative ideas for inspiration to create your own designs.

“To give an example, that kerfing plane (pictured below) came from Tom Fidgen, but I made it my own using my grandfather’s piece of wood, and I added some other things in terms of design.

“And don’t be afraid to fail! You have to waste wood to make something beautiful. There will be waste that comes off of that wood but you’re getting rid of what you don’t need to really show the beauty.”

Robert also heartily recommends the books and classes on woodworking with hand tools from Tom Fidgen’s The Unplugged Workshop. 

On behalf of the entire New England Forestry team, congratulations to Robert. He won the Small Indoor category in our employee DIY Contest!

You can read more of our DIY stories featuring talented woodworkers here.

The post The Woodworkers of Rayonier: Robert Hall appeared first on New England Forestry Stories.

The story behind the design of Laura Peacock’s rustic DIY wooden cooler pays homage to the man who taught her not only about woodworking, but also about what it means to make the most of what you have and to be a blessing to others.

Like father like daughter, in more ways than one!

Laura learned the basics of woodworking from her father while growing up in small town Florida. His woodworking skills were born of necessity and honed for pleasure as a young man. He was a Vietnam veteran who did most of his woodworking outdoors or in his shop, which is what drew her to the craft.  “My brother and I gravitated towards whatever Dad was doing because it was outside and we were outside most of the time. So we were naturally drawn to it.”

“My dad was one of nine kids, so they didn’t pay people to do things they could do themselves. My dad picked up woodworking to help out around the house. He wasn’t great at it for a long time, but he crafted his skills and eventually got good at doing a lot of different things.”

“We mostly learned from watching him. Our family was really close and we did everything together. We wanted to work together, whether it was canning season, building a deck, adding a room, or building a birdhouse. Except there was a line drawn between my mom and dad, dad didn’t cross to mom’s quilting and she didn’t cross to his woodworking territory!”

Ironically, Laura’s father worked for New England Forestry in the Fernandina paper mill (New England Forestry owned the mill until 2014, when New England Forestry Advanced Materials spun off into its own company). “It’s funny to think that my Dad retired from Rayonier, now I work for New England Forestry and we both share that love of woodworking.” Like father, like daughter, in more ways than one.

Though Laura’s father passed away from lung cancer about 7 years ago, her family still continues their traditions of helping one another and others. Whether it’s helping each other with woodworking projects, volunteering at church, or helping a disabled neighbor mow his ditch, Laura’s father instilled a strong sense of generosity, dependability and community in his children.

The story behind the cooler: inspired by pallets, made from fencing panels

Laura’s cooler, a finalist in the New England Forestry employee DIY Contest, was inspired by her friends in Nashville. They asked her to help them build one out of pallets.

“I saw the picture and was like, heck yes!”

But Laura had other plans in terms of design and execution.

“My Dad was actually doing pallet crafts long before it was a thing. When I got married, he built me what seems like an 800 pound china cabinet out of pallet boards. So, I knew what a chore they can be to take apart.”

Keen on avoiding the chore of pallet dismantling during her next visit to Tennessee, and eager to surprise her friends with a premade gift, Laura figured out another way to build the cooler.

“I really like taking a design and figuring out how to put my own spin on it. I had just repaired my privacy fence and I had fence panels. So I said, forget about pallets, I’ll just use these. It worked out perfectly!”

For the cooler itself, Laura bought a basic red chest cooler and built a rolling rustic cabinet around it. She removed the top from the cooler and built a wooden lid to fit. Then she added a spout on the side for drainage using basic plumbing hardware (a pipe and a spigot).

“So, I had the whole thing made, but led them on to believe we’d go find some pallets and build it. They were so surprised! I’m like that. If you give me an idea I’m probably going to try it out.”

In addition to its good looks, the cooler is also super functional, as it can be rolled around to different parts of the yard, to block parties, etc. She even included a small chalkboard sign on the cooler that can be customized for special occasions.

“I’ve built about 5 of them now and have yet to finish my own! But that always seems to happen because I love giving my stuff away.”

Woodworking as a hobby and a side hustle

Laura not only builds and designs beautiful coolers and furniture, she’s also created a side-job making door hangers out of plywood (pictured below).

“So woodworking has also become a great way to make some extra money, but I mostly just enjoy doing it. Especially these days when people are starting to appreciate handmade items more. That’s another thing, I feel like my Dad and I started doing these things (like working with pallets, making custom door hangers, etc.) before they became trends.”

Thanks to the skills she learned from her father, Laura was also able to do most of the renovation work on what she lovingly refers to as her “new-old-home,” including installing crown molding and replacing sheetrock. A big sell-point of the home was the 3-car garage, which meant she now has more than enough room for a woodshop and storage.

As a hobby, Laura derives great pleasure from transforming raw materials into the finished product. But ironically, she does not consider herself a “creative person.”

“I never felt like I was a really creative person. But I don’t have to be creative, I just have to be a copycat! I have the tools and I have an ability to take something that’s not and turn it into something that is, and it makes me feel good.

“The ties to my family history, and just seeing people’s faces when they unwrap a camper door hanger to hang on their camper door…I just love to make other people happy.”

Bridging the gender gap in woodworking: advice for women who like power tools

For whatever reason, woodworking has been a predominantly male pastime. Yet women are perfectly capable of mastering the art and skill. Here’s Laura’s take on the gender gap and how women can get past it and join the party:

“I’m in my mid-40s, and for people like me and older, there’s a line that’s been drawn about what men do and what women do. As women in general, and it’s easier for us to limit ourselves based on those old stereotypes. But know that it’s okay to break the mold a little bit. Because the thing is, if you want to learn something these days you can learn how to do it. There are thousands of resources out of there.”

“As my mom would always say when I’d ask her if I could do this or that, ‘Why not?!’ Give it a shot. The worst that can happen is you’re out a bit of money for materials.”

“I used to teach, and I’d tell my students that if they could read they can do anything. You don’t even have to be able to read these days. Just ask Alexa, Siri, or tell your TV remote what you want to see. Knowledge is power, learn all you can and become all you can. There are no limits!”

You can read more of our DIY stories featuring talented woodworkers here.

The post The Woodworkers of Rayonier: Laura Peacock appeared first on New England Forestry Stories.