Large 5 Ft Map Of Long Island

We were contacted by an American customer requesting a map of Long Island and they wanted it to be large. We love doing the bigger maps. She was looking through our “Previous Works” page and came across this map we did a few years ago.

She asked for her map to be 6 feet long. While we were working on a quote including shipping to the US, we discovered that the box was going to be too big to be shipped through Canada Post. Next we contacted UPS and their limit with size is 5 feet. So that’s how we arrived at making this map 5 feet long.

First thing we did was size out the map on the computer and send the print job to the printer to get a copy for cutting out the map.

Like all good things, this project started in the workshop, selecting boards. Here is an example of boards we were choosing from. Hard to believe they will make a beautiful map but they do.

As you can see from the boards above the color varies greatly depending on the species of wood and how long they have been weathering. (Is that even a word?) Her main request was she didn’t want grey, she wanted more of a brown appearance to the map. We can only do our best, the rest is up to Mother Nature. Know what I mean??

After selecting boards, Jim headed to the tablesaw and sliced the weathered portion we needed of each side of the 2 x 4s.

Before we went any further with these boards, we decided to make the frame first. That way we can adjust the boards to fit the frame rather than the other way around, which would be harder. Been there, done that.

We wanted all sides of the frame to be weathered so that makes things a little trickier but manageable.

The corners got holes pre-drilled and glued and screwed with brass wood screws Jim had in his screws drawer that were likely left over supplies from a project he did 20 years ago. He tends to not throw things out, he suffers from “Might Need It Later” syndrome. Then again, he said the same for the weathered 2×4’s that have been around for over 10 years. Here we are making maps from them.

He then routed the frame from the back so the map can sit within the frame and near flush with the back of the frame. Got that?

Now back to the boards. These are some of the boards we chose.

Each board was edge jointed on the jointer.

And a little more trimming.

All projects get a good sanding and that is especially true for this one since she didn’t want an overall grey appearance.

With all the boards prepped, it was time for glue. Each board was glued on one side and the glue was spread out to cover the whole edge with a very technical tool called a finger.

Once all boards were glued, it was time for clamps.

The next day, once the glue was dry, we test fitted the frame.

Normally I would be already painting the back board but we were out of luan plywood that was big enough. Had to make a trip to the hardware store.

No time to waste though, Jim got set up to cut out the map on the scroll saw. For larger maps, years ago Jim built himself an extension for the scroll saw. It comes in handy for sure, allowing the project to roll in which ever direction is needed on these handy rollers while supporting the long panel.

With the paper pattern taped in place to the boards…Jim drilled quite a few pilot holes for the scroll saw blade since there are a number of smaller islands to be cut out as well.

It took I don’t know how many hours to cut out this map spread over a couple of days. Every time I came out he had made quite a bit of progress, but still slow going on this very rugged coast.

The only thing left was to go to the hardware store and pick up thin plywood for the backboard. Once home, Jim cut it to size and I gave it two coats of white paint with a sanding between coats.

With all three pieces complete it was time for them to become one. We used glue between the weathered boards and the white backer board.

Then for added assurance since this is going on a journey, we added short nails with the nail gun from the back.

Next was to add the frame. Again with the nail gun and a bit longer nails, we shot through the backer board into the frame from the back.

To the back of the frame we attached a wire for hanging. This thing is heavy. I did the old stand on the scales alone and with the map trick and guess what!! It weighs 12.6 llbs.

Here are a few of the details on the map:

There was one spot where a knot had fallen out of the wood and the white paint was showing through, so I grabbed a tiny brush and added a color that would blend in with the weathered boards.

Here we have our model for today… Jim… wearing the latest in flannel… holding the newest map… Long Island, New York, in the good ol’ USA.

Time to get this boxed up and out the door so someone can enjoy it for Christmas.

Later