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Much like the Hickory used on the shafts, our Red Oak is native to the Appalachian Mountains of Eastern Pennsylvania… Because of the rich soil and climate, this is one of the best areas for quality Oak.
Oak was selected for the displays because of the fancy and unique grain characteristics. It is also one of the more durable of the hardwoods.
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Our Select/FAS Graded Oak is kiln dried using forced hot air generated by burning the woodchips from the scrap portion of the tree.
FAS is the highest grade wood available ranked according to straightness and clarity (on low to no knots). Great care is taken to ensure the humidity is maintained within acceptable levels to prevent warping of wood.
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Each piece of the final assembly is cut to size and prepared for the gluing operation by sanding the joining edges. A special machine is used for this process to ensure that each piece perfectly matches up with its mating piece.
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Proper clamping is the key to properly joining the pieces together. It is very important to join these pieces in the proper grain pattern. This nearly eliminates future warping of wood. We apply an aliphatic resin glue that provides a superior bond which is even stronger than the wood itself.
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Each piece has a specific pattern that is used to achieve the outline of the cut path. Using an industrial jig saw, the pieces are cut to the exact size of the pattern.
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After parts are cut to pattern, the rough sanding process is used to remove any rough edges and make sure that the shape of the piece matches exactly with the pattern specifications.
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Each piece is processed on the router to achieve the stylish edges on each of the displays. This process is also used in combination with other tooling to achieve the putter cup at the front of the floor display.
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This belt sanding process ensures that the surface of each piece is perfectly flat, smooth, and free of any surface blemishes.
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Each piece is then painstakingly sanded by hand to get the exact desired finish on every surface. The corners and hard-to-reach crevices are hand sanded to ensure a uniform finish with the rest of the surfaces. In some cases this can take up to 35 minutes or more on each piece.
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All of the sanded pieces are then carefully positioned and assembled to the other pieces using the superior bond glue and tack nails.
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Our 7-step staining process is one of the most critical in ensuring the perfect look of each display. There are multiple cycles of stain applied, intermixed with hand sanding operations. A final hard coat is applied to increase luster and durability of the wood.
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The application of felt is very tedious. Each piece is cut to fit exactly into position and is not very forgiving. Any error in the application of felt could destroy the entire display and cause it to be scrapped.
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The holding arm is precisely fabricated using CNC turning to thread the end (pictured here), forming and bending equipment to create the form of the putter holding arm and fingers. The pieces are then tig welded for a clean and strong weld. Welds are inspected for aesthetics and cleaned up, if necessary. The surface is then cleaned and prepared for gold painting.
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The final component of the process is fitting the holding arm to the floor display base to ensure that the pieces fit perfectly together. You will have to assemble these pieces when the display arrives, but we test them here to make sure the fit is to our demanding standards.
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