I'm in the process of designing a new project for the wife, she is my client. After all these years that she has put up with my woodworking obsession: the tools, lumber, the dusty messes and the late night reading of every piece of material I could get my hands on, its time I pay her back. The project is to build something for the dining room that will both store dishes and silver while providing a serving area for platters or drinks. She has a finely tuned palette when it comes to furnishings so I really need to take this to the next level to meet/exceed her high expectations.

I've really enjoyed this site the past 6 months and wanted to use the design form to see if I can work out some remaining design issues and get some feedback from the group as I build it over the next few months.
The design inspiration started by scouring the web, old wood mags and books looking for every early American period hutch, china cabinet, cupboard that I could find. After presenting a dozen influential pieces to the "design committee", she seemed to gravitate towards the look and feel of the Pennsylvania, Connecticut, New York "country" looking pieces. Not rough pine but pieces without a lot of intricacies, inlays or fancy brass. Just somewhat elegant simple pieces with flat surfaces, Chippendale influenced bracket feet, large moldings and exposed joinery.
The material that the hutch will be built out of is some Tiger/Curly Hard Maple I've been stock piling the past few years. I have a few different lumber grades from AAAAA Fiddle back Tiger Maple to medium curly stuff. That would be the primary wood, poplar would be the secondary wood and I'm also considering the possibility of incorporating in some Birdseye or Ebony for "pegs or knobs" if appropriate.
The finish that catches her eye is a nice rich antique maple color with a top coat of blonde shellac. But the exact formula to be used needs to be experimented with and proven, after generating a few samples and being able to repeat it two or three times is the point where I'll sign off on anything.

I would love to get some suggestions from anyone that has experience with Tiger Maple.
Robert Millard has a great tutorial showing one technique I would love to try out but my wife wants it a little darker in shade.
I want to make sure and do this project right from the start, so I've kicked it off after some quick paper drawings using Sketchup. I have about 15+ hrs. in this model that I've built so far but the time has been so valuable as I run into issues that I never thought about before. And I would rather solve them digitally versus half way through the real thing. It has really pushed my boundaries with the application and helped me learn how to create Ogee Bracket Feet and incorporate real joinery.
Here are a few exported pictures from Sketchup showing the preliminary design:
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File comment: Hutch Cupboard Frontal View with Dimensions
hutchFrontMeasures.png [ 29.74 KiB | Viewed 667 times ]
The model is still missing a few items such as backer boards, drawers, cabinet doors and hutch single pane doors. Two dimensions that I overlooked is the depth of the top hutch: 14 inches and the bottom cupboard with is 20 1/2 inches. As you can see there are a few measurements that have a phantom 1/64" added or missing from an inch.. not sure how that happens.
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File comment: Hutch Cupboard ISO View Showing Joinery
hutchISOJoineryDetail.png [ 54.99 KiB | Viewed 654 times ]
When possible I've been adding joinery details to the piece to allow me to workout the layout and a more detailed build outline.
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File comment: Hutch Cupboard Underside View
hutchUndersideDetail.png [ 65.2 KiB | Viewed 638 times ]
This image shows the backside of the Ogee Bracket Feet with the hidden support material. The feet are 4 1/4" high, 9 3/8" long and 1 3/4" thick. These feet are pretty close to what I pictured the final piece using, but they need some work and I might work that out using the full size patterns.
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File comment: Hutch Cupboard Top Molding View
hutchCrownDetail.png [ 28.53 KiB | Viewed 634 times ]
I'm in the process of designing the profile for the three moldings. The top molding will most likely be a buildup of several pieces of wood due its size and added flexibility to make. Moldings have only been added to one side of the project to minimize the Sketchup work until the profiles are finalized.
There are a number of construction, design and joinery unknowns that are haunting me, here is a quick list of a few:
1. The design was initially influenced by the desire to maximize space, lift the hutch to give 12" of space for plates and misc. Does the overall proportion or the whole piece, the top, the bottom.. individual drawers work for you? I know this might be a bit premature to work on until the moldings, doors and drawer fronts are incorporated.
2. The backer boards are one area that I need to get some advise on, I would like to do some ship lapped 1/2" boards along the back with a potential bead incorporated. As for the a vertical versus horizontal orientation, what about color? Should they painted white, light blue or left finished like the rest of the piece?
3. The molding profiles so far have been influenced by profiles of wooden planes that I currently have but that is pretty limiting so I'm still searching for a molding reference site. Do you have any suggestions or resources?
4. This is the first large case piece that I've worked on and I was wondering about the base construction, how the bottom molding and bracket feet are attached. Should a center support be added since the current design has the piece spanning 70".
5. My design around the center draw area incorporates solid vertical dividers. From a structural aspect is this design correct? Wood movement shouldn't be an issue since the grains will all be moving in unison.
6. Initially I planned on using poplar for the bottom of the carcass but after reading a thread Tommy posted yesterday about only using secondary wood where it is not seen I'm thinking about using some "less" figured hard maple for the bottom. It looks like the only use for poplar is for the drawer slides and underneath bracket feet supports. Does that seem like a correct use considering all the stresses applied to the feet and given how soft poplar can be. Should I use hard maple for the bottom.
7. Laying out the stock. Once I start to pick where each piece of lumber will be incorporated I wanted to run by you my list of prioritization for the use of the better grades. The drawer fronts and cabinet doors will get the best figured stock followed by the cupboard top, case sides, moldings, bracket feet and the face frame. How does this ordering work for everyone? I would love to hear your suggestions.
8. The face frame. Is this something that would commonly be incorporated in an older period piece? It just seemed like a logical way to design the piece given the drawers and cupboard construction. If so, were they attached using just glue or were other mechanical "pegs/nails/screws" used to fasten them?
I guess that is enough for now. I'm looking forward to feedback and hopefully I can keep this project on schedule and regularly post my progress and obstacles to ensure an on-time April/May delivery time frame to the misses. She thinks it won't get completed until after next September.
