That's right, an 8' x 6' mahogany corbel. We have been asked to build several corbels with a 4" x 6" x 8' vertical piece on the wall and a 4" x 6" x 6' top (horizontal) piece. The curved portion of the corbel that connects the bottom of the vertical and the outer end of the horizontal is 11 1/2" wide by 5" thick. This is really going to look like a substantial corbel from the side where you will see the 11 1/2" wide part. We have been bouncing around ways of building them, as the architect does not specify any particular method. Any suggestions on the fabrication?
(Architectural Woodworking Forum)
From contributor R:
I would do this on the CNC. Three layers of 1-1/2" mahogany could be cut into any profile and drilled with alignment dowels (stopped on the two outer layers, and through in the middle). With proper grain-matching, this would look good. You could also machine a tenon on the middle piece, and mortise it into the top and bottom, along with lag bolts from the back. The two "beams" could be either box-beam construction or solid (same layered technique). If they are box-beams, they could have mitered corners, but I think butt or rabbet joints would look fine also. In my experience, most architects and designers go for darker finishes on mahogany, so a lot of fussing on joint selection becomes moot after they put shoe-polish on it.