Post 5: Upcycle Design Report

Introduction:

For my upcycle project, I chose to create a cabinet dartboard with an old Western aesthetic. Specifically, I wanted the project to be based around an old-Western saloon. I decided on this project after being interrupted by one of my roommates while brainstorming ideas. I remembered I had an unopened dartboard at my parents’ house and figured I could design something involving it to keep my roommates and me entertained! I then made a connection between the mention of used cabinets at Resource Central (a salvage yard full of old cabinets, sinks, and various home improvement materials). I knew making this project would be really rewarding because it’s an artifact I will use and can bring wherever I move in the future. The dartboard brings friends and family together, and I think it will be really fun explaining to new users that I built this for a college class project!

Inspiration – Old Western Saloon:

After the brainstorming phase, I conducted extensive research on cabinet dartboards as well as the Western aesthetic. I started looking at different designs, how they differed from each other, optimal cabinet dimensions, and analyzed the functionality of the cabinet. I wanted to get a good idea of what materials I might need and, most importantly, what I should look for when selecting a cabinet to upcycle at Resource Central. After determining that I needed a cabinet no larger than 30″ x 30″ x 12″, I began to explore the Western aesthetic in greater depth.

When I first thought of the idea, the aesthetic that immediately made the most sense was a Western theme. Most 21st-century Western bars have games like pool and darts, so the two combine well as a whole. I had previously visited several Western-style bars and restaurants, and most featured darker lighting, with some utilizing dark wood and others incorporating lighter, stained wood as their main material. Saloons often have a rustic, vintage look and feel, achieved through objects such as bull horns, taxidermy mounts of bucks and fish, barrels, scratched-up wooden chairs and tables, hanging lamps, and small trinkets on shelves. I planned to incorporate as much of this Western aesthetic into my project as possible.

Early Project Vision:

In the early stages of the project, my first objective was to find the right cabinet for the dartboard. My goal in searching for a cabinet was to find one that required as little modification as possible while still allowing the dartboard to fit snugly inside. This was the most critical part of the project—if I couldn’t find the optimal cabinet, I would need to spend much more time in the machine shop cutting down the cabinet boards to fit my needs. There is a lot less room for error when making modifications like that, so I wanted to avoid unnecessary headaches by finding the best cabinet possible. Luckily, I found the perfect cabinet, with dimensions of 23″ x 27″ x 4″. I initially assumed I would need to modify it at least a little, but since it was exactly what I needed, I left it as it was

Once I found the cabinet, I visited various thrift stores and Art Parts (a discount craft store) to look for anything that fit into the old-Western aesthetic. At Salvation Army Thrift, I met an employee who enjoyed arts and crafts. She helped me think outside the box, suggesting ideas like using belt buckles and jewelry. Although we couldn’t find anything there, I wanted to mention her as a source of inspiration in brainstorming ways to incorporate the Western theme into the project. From there, I browsed a few other nearby thrift stores and found some great items: a toy cow, a small gas lantern, an old Pepsi jar, and a picture of a vast desert. I figured these small items would be perfect for the bottom shelf and would add some Western flair to the cabinet.

 

 

 

 

 

 

 

 

 

 

My primary vision for incorporating the Western saloon style was through the doors. Instead of attaching the doors to the top of the cabinet, I wanted to position them in the center, leaving open space on the top and bottom when closed. This would emulate the swinging-door style of old-Western saloons while still concealing the dartboard inside. Initially, I wanted to cut the doors into a distinct “wave shape,” but I eventually decided to omit this because the original doors had a trim that might have looked awkward if cut. I liked the look of the doors as they were and didn’t want to create unnecessary problems. I decided to play it safe, knowing I could always create new doors later if I had time.

Fabrication Process:

The fabrication process was fairly straightforward since I didn’t need to cut much. First, I removed the doors and stained both the cabinet and doors with an oil-based stain. I chose “Early American,” a moderately dark finish that gives an old-Western look, from McGuckin Hardware. This was my first time staining wood, so I don’t think I did the best job, but I believe the stain I chose is perfect for the aesthetic. My first coat was too heavy, and I didn’t wipe off the excess well enough, causing it to remain sticky for a couple of days. I applied a top coat to fix some of the imperfections, using a much lighter application of stain. This made the finished product look much better than after the first coat.

Next, it was time to mount the dartboard inside the cabinet. I ran into a slight issue when I realized I needed to add additional wood to the back of the cabinet, as the nails for the mount were much longer than the cabinet’s backboard. Fortunately, I found some spare wood in the ITLL woodshop, along with some screws. I duct-taped three wooden boards together, then secured them with a few screws. Once my pieces were “half-secured” to the cabinet, I measured the exact center of the cabinet and nailed in the mount, aligning it with the bullseye placement.

The biggest challenge came when re-mounting the doors in the center. Initially, I tried drilling the screws straight through the wood, but this didn’t work because they weren’t self-tapping screws. I needed to drill pilot holes, so I went to Home Depot and bought a drill bit. However, the bit diameter was slightly too small, causing me to tear up the wooden hole I had drilled and preventing the screw from sitting flush. This was frustrating, as I had to move one of the doors slightly upward and re-drill, a process that took several hours due to the lack of clamps and other helpful tools available in a woodshop. I wasn’t able to get the doors perfectly even in time for the due date, but when presenting the project, several people commented that the uneven doors added to the old-Western aesthetic. Thinking about it, measuring devices back then were likely inaccurate, so some saloon doors were probably pretty crooked or uneven!

Final Product:

I am really happy with how my final product turned out. I encountered a few challenges along the way, but that is to be expected in any project. I worked through these challenges by staying optimistic, creative, and assertive. I can definitely see the rustic, old-Western look through the color of the cabinets, the Western trinkets on the shelf, the swinging saloon doors, and even the dartboard itself, which looks slightly worn and old. Functionally, it works perfectly! I still need to hang it, but I tested it out by throwing darts from a lower level. The only concern I have is that the misaligned door was mounted slightly too far inward, preventing it from swinging open past 90 degrees. I may need to fix this, as it could affect the dart thrower’s depth perception and vision.

Improvements:

To enhance my project, I would love to add a small saloon sign at the top of the cabinet to further emphasize the saloon aesthetic. Another addition could be a chalkboard on the inside of one of the doors for keeping score during dart games, a common dartboard feature. I also mentioned fixing the door so it swings open past 90 degrees. I could also address the unevenness at the same time, but I might keep that feature—let me know your thoughts!

Overall, this project was a blast. I now have a fun new way to bring people together that I created myself!