True I.D. Stories #24: The Accidental Designer, Part 6 – Forget Hollywood, We’re Going Big Time!

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Editor: After going Hollywood in Part 5, here in Part 6 Accidental Designer finds a casual suggestion from his wife is about to change their lives. As one door closes, another door (this one on a shipping container) opens….


I was down in my basement workshop, failing.

I had been trying to produce a lightweight and affordable bamboo folding chair for Hollywood sets. After hundreds of hours and countless prototypes, this problem just had me beat—and I knew it. I mopped my brow and called up the stairs to ask my wife if we had any sandwiches left.

My wife is a mean cook and she goes through cutting boards like nobody’s business. It doesn’t matter what they’re made of, she just plain wears them out. “I need a new cutting board, this one’s through,” she called down the stairs. “Can you scrape up some of that bamboo and make me one?”

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I looked around at all of the bamboo scrap I had and thought, well, here’s a problem I can solve. I glued up a bunch of scrap pieces, more than I needed just for the sake of doing something, and by the next day I’d made her a cutting board and a few back-ups.

Following that, to clean up my shop area, use up a bunch of scrap and exercise my brain, I threw myself into gluing up cut-offs and began experimenting with different styles of cutting boards. After failing with chair prototype after prototype, it felt good to successfully make something—anything.

I had consistently-shaped scraps in several different sizes, and so I designed the cutting boards around the shape of the scraps. By the end of my clean-up project I had several dozen good-looking cutting boards. I felt like my table saw and router respected me again.

I didn’t think much of this until a few weeks later, when I was loading up my truck to hit a craft show in Arizona. I was bringing the $2,000 bamboo chair even though I knew it wouldn’t sell, and also bringing some consumer-grade chairs I knew I could sell, just because I needed the cash. The extra bamboo cutting boards I’d made were sitting in the corner. I figured they’d be Christmas presents for relatives, which would save my wife and I some cash since we were getting close to broke.

Still, I grabbed a bunch of the cutting boards and threw them in the truck. I didn’t think I’d sell any, but figured I’d use them to gauge interest.

Maybe you can guess what happened next.

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True I.D. Stories #23: The Accidental Designer, Part 5 – Going Hollywood

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Editor: Here in Part 5, Accidental Designer gets a taste of the Big Time with a little help from Hollywood; pisses off several hundred propmasters; and finds himself faced with a serious production challenge.


Tradeshows are expensive to get into, but they can be an important part of growing your furniture business. You never know who’s going to walk into your booth and change your life.

I’d started selling my tall, padded folding chairs at movie industry trade shows, and there would be a line leading to my booth. The chairs were apparently perfect for Hollywood sets. The orders were still individually small, five chairs here, ten chairs there, some orders as small as one. But I didn’t care how small they were and I’d still deliver the units myself. In fact, I’d stopped driving the Ford Ranger pickup and bought a used 15-passenger van from a Korean church; I’d ripped out all of the seats to turn it into a cargo van.

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Anyways, one of the people that came into my booth was a makeup artist with a small order. I delivered the three chairs myself to the Warner Brothers lot in Hollywood.

Well, turns out that person was one of three makeup artists for The Drew Carey Show. This was the ’90s, and the peak of that show’s success. And I found myself hauling those chairs onto that set.

I’m setting one of them up, and who should walk past but Drew Carey himself.

“Hey,” he says, pointing at the chair, “whatcha got there?”

I told him that I designed, built and sold these chairs, and started pointing out the various features. Drew seemed interested. “You mind if I—” he gestured, then sat down in the chair himself to try it out. He wriggled around a bit to get comfortable.

“These are so cool!” he exclaimed. He jumped up out of the chair. “Give me one of these for everybody on the set!” He then hustled off to do something else.

I looked around, trying to figure out how many people were on this set. I’m naively thinking it’s a couple dozen, and I’m standing there counting people with my fingers when one of Drew’s headset-wearing assistants hustles over to me with a clipboard. She places an order with me for 120 chairs.

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True I.D. Stories #22: The Accidental Designer, Part 4 – I’m Not Gonna Take Your Craft Anymore

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Editor: Here in Part 4, Accidental Designer comes face to face with someone he’d been looking to avoid. Following that encounter, his subsequent talent for design accidentally gets him the attention of Hollywood!

Previously: The Accidental Designer, Part 3 – Is This Seat Taken?


“Hey man,” Rusty said. He introduced himself even though I already knew who he was. “I’ve been following you for the past few.”

“Oh, ah,” I said. What was there to say—what could I possibly say? All I could do was apologize. “Listen man, I’m, ah, sorry—so sorry that I took your, uh—”

Rusty cut me off. “What are you talking about, man?” he said. “Your chair looks awesome.” Your chair, he’d said.

“But I took the design from you,” I said.

“Yeah, you did, and I took the design from somebody else. And I made it a little bit better. And that guy I took it from, he took it from someone before him, and he’d made it a little bit better. This chair has been around for ages, dude,” he said. “And yours looks awesome.”

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I was so relieved, and felt a huge weight come off of my shoulders. Now don’t get me wrong, I’m not saying you should all go out and steal someone else’s designs. These days, things are copyrighted and IP’d and everybody’s all lawyered up. But that sling rocker chair had come into the world iteratively, like shipwrighting skills. People got better and better at it and the product improved through succession and collaboration. No one owns a shiplap joint and back then no one owned that chair (though I’ll betcha someone with lawyers does today).

Rusty and I remain good friends to this day. But before you think I got off easy for taking that design, well, I didn’t. Rusty might not have given a damn, but though I didn’t know it, the karma was going to come back around one day.

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True I.D. Stories #21: The Accidental Designer, Part 3 – Is This Seat (Design) Taken?

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Editor: Have you ever been tempted to take someone else’s design? What do you think would happen to you if you did? Here we’ve got Part 3 of “Accidental Designer’s” story, as he follows through on a fateful decision.

Missed the last one? Catch up here.


At a craft fair I’d spotted this guy, I’ll call him Rusty, selling these chairs he had made. As soon as I saw his design, I realized I could build them myself, even better than he had. And I darn sure had enough wood to make them. Now I have to point out that these chairs were not my design. But before we talk design theft, I have to detour into auto theft. Because in my life there were two cases where people were getting rid of a boatload of wood and it worked out in my favor, and with the first one I ended up getting my car stolen.

Some guy was selling a garageful of teak, which I’d mentioned earlier. These were huge pieces of rough-cut lumber and you couldn’t believe how much of it there was. The guy’s grandfather had brought it all over from India on a ship in the 1950s. I had this crappy Chevy Astro van, and each trip I loaded it up to the brim with wood, so badly that the van was practically bottoming out. It was a 1.5-hour round trip and it took me six freaking trips to get all of the wood back to the boatyard where I was living.

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By the time I made it back with the final load, it was late at night and I was dead tired. I couldn’t lift my arms to unload that last batch and figured I’d get to it in the morning, so I left the car in the lot, staggered back into my sailboat and fell asleep with my boots on.

In the morning I got up and went out to finish the job. But my van was gone. I always parked in the same spot so it’s not like I misplaced it, and the keys were still in my pocket, so it’s not like a buddy of mine had moved it. It had just disappeared, along with its load of valuable teak.

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True I.D. Stories #20: The Accidental Designer, Part 2 – Learning All Kinds of Ship

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Editor: Here in Part 2 of “Accidental Designer’s” story, he engages in one of the more unconventional design/build educations we’ve ever heard of—and unwittingly lays the foundation for a big next step on his way to starting his own company.

If you’re behind on this tale, you’ll want to catch up with Part 1 first.


It amazes me that those of you in design school learn your craft in four years. Since I had no plan, I spent well over a decade building up my skillset and learned a lot of things the hard way, though I don’t regret a day of it.

After graduating high school I had no notion of design as a career, and more immediately I knew college wasn’t for me. Neither was staying in my mom’s house. So at 18 I moved out, and started living on a derelict wooden sailboat that my brother and I had bought with money we’d saved up working for my dad.

With every dollar we had spent on the boat, there wasn’t anything left over for paying for a space to dock the boat. So my brother and I became experts at “the slip-around,” where you’d find a slip someone had recently vacated, then dock the boat there. Eventually Harbor Patrol would realize your boat was in a slip that someone had stopped renting, then you’d get towed to the impound dock. But it didn’t take a genius to figure out that paying a $35 fine a couple times a month was a helluva lot cheaper than the $300 monthly rental fee.

I supported myself using the skills I’d learned under Mr. Barkington in that hellish Shop class, particularly that last big boat restoration job. I had also taught myself some new tricks through trial and error, and I talked some folks into hiring me to restore their boats. With the money I saved I was able to buy some boats of my own, real junkers, but I’d live in them, restore them, flip them, then buy another, rinse and repeat. That worked out pretty good.

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People got to know my face around the marina, and I got hired to do odd jobs around the place. Instead of the Harbor Police writing me tickets, I became the guy they’d call if a boat was sinking in the harbor, and I’d go pump it out. If someone showed up in the middle of the night for an early-morning haul, I’d help them get set up. Because I was there practically 24-7, I became the boatyard’s de facto security.

Eventually I caught the attention of the local boatyard. They had this old-school shipwright, a really crusty old-timer who wanted to retire, and he needed an apprentice who could keep the work up. I’ll call him Mr. Wright, and I’ll tell you that this guy made Mr. Barkington look like a kind, nurturing soul.

But I wasn’t there for praise, and apprenticing under an old-school guy like that, who really knew his business, was one of the best educations I could get. Soon I was living in the boatyard with my own, legal, slip. And for the next eight years Mr. Wright taught me proper process and procedure, along with a system of wood joinery that was centuries old. He taught me how to balance following tradition with thinking on your feet. I got to use all kinds of unusual shipwright’s tools, like a handplane with a bowed, springy bottom so you could plane concave surfaces, tools the likes of which I never saw before or since. He had this special kind of adjustable “story stick” that he used to measure windows, he called it a “Preacher stick.” I asked him why and he looked at me like I was an idiot and said “Because it never lies.”

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True I.D. Stories #19: The Accidental Designer, Part 1 – Shop to Hell

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Editor: Here “Accidental Designer” tells us the epic tale of how he backed into a career in designing and building by discovering something no one else had. We won’t tell you the name of our protagonist for now, as we don’t want you to Google him yet and find out how the story ends. Just sit back, enjoy, and see how a man with no formal industrial design training launched into a career many of us would envy.


I knew that I’d screwed up, but knowing it didn’t make it any better. I was made to stand up in front of the class, where thirty pairs of wide eyes all stared at me, afraid of what was going to come next, yet glad that it wasn’t one of them up there.

You see, before I had any inclination that design was going to make me a success, and before I even learned how to design, I learned how to build. I read in a previous True I.D. Story that the designer learned how to build in his grandfather’s woodshop as a kid. Well, I didn’t have a kindly grandfather teaching me: Instead I had a hard-ass I’ll call Mr. Barkington, who ran the Wood Shop class in my high school. And I thought he was a complete asshole.

Wood Shop was a mandatory class, and Mr. Barkington was quite the ball-buster. For our first assignment, we had to make a checkerboard—pretty basic, cut squares out of two different colors of wood, then put them together in an alternating pattern. Well, I forgot to account for the kerf, the thickness of the blade, when I cut my pieces up. Add up a 3/32″ kerf across the entire board, and by the time I got it all together the damn thing was a couple inches too short on each side.

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Mr. Barkington called me out in front of the entire class. “Take a look, everybody,” he said, “take a good look at what this fucking idiot did! Jesus Christ!” He held my board up so everyone could see. “Does that look right to you? Hey asshole, do you even know what a kerf is? Jesus, Saint Mary and Joseph!”

As you Millennials can probably tell, I went to high school a long time ago, back when it was perfectly acceptable for a teacher to say these kinds of things to a student. Today Mr. Barkington would probably have been fired, but back then, I dunno, I think we didn’t take stuff so personal, or we learned to endure it for our own betterment. When he humiliated me in front of the class, sure, my cheeks were burning, but I didn’t cry, or go tell the Principal (who wouldn’t have given a shit) or go whine to my parents. And no, I didn’t throw the checkerboard out; it became a cutting board for my mom.

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True I.D. Stories #18: This Job Interview’s in the Bag

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This is a true story. Descriptions of companies, clients, schools, projects, and designers may be altered and anonymized to protect the innocent.

Editor: This True I.D. Story comes to us from “Diceman,” who landed a killer I.D. job straight out of school—then fell on harder times when the market shifted, and had to go back out on job interviews.


I was on time for my interview at the softgoods company. Five people filed into the room, a mix of junior and senior designers and the company’s Design Director. After exchanging pleasantries, we got down to brass tacks and I cracked my book open.

I started off by showing my sketches, which, frankly, are not my strong suit. I hoped to blow past that and get to the things I was good at, modelmaking, CAD and fabrication, but the interview took a left turn. There was some general murmuring about the weak quality of my sketches, which I could handle—design school crits can be brutal and do a good job of fortifying you—but this one junior designer clamped on like a pit bull and just wouldn’t let go. He kept going on, and on, and on about my “shitty” sketches; I looked around the room to see if anyone was going to rein this guy in for saying the word “shitty” during a freaking job interview, but all I saw were disappointed eyes looking at my book.

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Ah, how far the mighty have fallen, I thought, reflecting on my last ID job, where I probably made more money than the Design Director did here.

Let me back up a sec and tell you how I got to this GD interview in the first place.

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True I.D. Stories #17: Why ‘Spinal Tap’s’ 11 is More Like 3.5

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This is our first non-anonymous True I.D. Story.

As a musician and sound engineer, Stephen Ambrose spent the ’70s touring the world with hard rock acts. This led him to invent the world’s first in-ear monitor, essentially the progenitor to the modern-day earbud. In this True I.D. Story, Ambrose—who went on to commercialize his invention by founding Asius Technologies—reveals why Spinal Tap’s “11” is, in real life, more like a 3.5.

Editor’s Note: This story is primarily paraphrased from a conversation with Stephen Ambrose, and is not comprised of direct quotes. If there are any factual and technical errors here, they are mine, and not Ambrose’s.


As a sound engineer in the 1970s, roadies used to hate me because I’d show up for the tour with 23 flight cases and they all had to be hauled; musicians, especially the hard rock guys I was working with, need to hear themselves on stage, and they like to hear themselves LOUD, the thinking went. So there was a lot of gear.

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Aside from the roadies, I had a financial incentive to develop an in-ear monitor; if I could make something that fit into your ear and gave you that crucial feedback, then you wouldn’t have to ship 10,000 pounds of speakers all around the world. The air freight on those speakers was pretty expensive.

A lot of [these rockers] had actually developed hearing damage from years of being up on stage, though they’d never admit it. Image, you know. So one challenge in designing my in-ear monitor was that it couldn’t look like a hearing aid, because no rocker wants to look like he’s wearing a hearing aid—even if he really needs one! So I made them out of gold so that they looked like jewelry.

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Core77 2013 Year in Review: The Year in True I.D. Stories

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Core77 2013 Year in Review: Top Ten Posts · Furniture, Pt. 1 · Furniture, Pt. 2
Digital Fabrication, Pt. 1 · Digital Fabrication, Pt. 2 · Digital Fabrication, Pt. 3 · Digital Fabrication, Pt. 4
Insights from the Core77 Questionnaire · Maker Culture: The Good, the Bad and the Future · Food & Drink
Materials, Pt. 1: Wood · Materials, Pt. 2: Creative Repurposing · Materials, Pt. 3: The New Stuff
True I.D. Stories · High-Tech Headlines

For 2013 we rolled out a new section, one that’s quickly become a reader favorite: True I.D. Stories, where industrial designers in our readership stepped forward (albeit anonymously) to tell their tales. What can go wrong for an industrial designer? The short answer is, lots.

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First, “Newbie Designer” sounded off with “Off the Grid,” the tale of his first ID business trip. The newly-minted exhibit designer was flown across the country to oversee a store installation, and the trouble started nearly as soon as he got to the store.

» True I.D. Stories #1: Off the Grid

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Next, “Design Minion” told us his story of “Fun in the Sun.” The designer of recreational pleasure craft found no pleasure during his first, hellish, on-site product catalog photo shoot.

» True I.D. Stories #2: Fun in the Sun?

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Then we got into epic tale territory, as “Good Ol’ Boy” took us through his multi-part adventure of going from useless, unskilled design grad to getting his dream ID job. It was by no means a straight line—this tale has more crazy twists and turns than a spy novel!

» True I.D. Stories #3: Get a Job, Any Job!
» True I.D. Stories #4: My Master(s) Plan
» True I.D. Stories #5: Game of ID Thrones
» True I.D. Stories #6: Opportunity Knocks. And Her Name is Amber
» True I.D. Stories #7: Money, Revenge, and Miscalculations

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True I.D. Stories #16: Man Up

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This is a true story. Descriptions of companies, clients, schools, projects, and designers may be altered and anonymized to protect the innocent.

Editor: The conclusion of “Family Man’s” cross-country tale! After he confronts his boss about shorting him on his salary, said boss suddenly drags him into another ID firm that shares the same building. How is this going to be a solution?


“[Jimmy the Bear], this is [Family Man],” Batcopter Boss said, introducing me. “He’s a talented designer. And right now he needs some extra work.”

I didn’t need extra work, as far as I was concerned; I needed to be paid the correct amount for the work I was already doing. But I kept my mouth shut for a second, to see just what the hell was going on here.

Jimmy the Bear got up and came around from behind the desk to shake my hand. I call him Jimmy the Bear because that’s what he looked like: A big, bearded gentle giant type, who moved and even blinked ponderously and deliberately. “How are you doing, Family Man,” he said, encasing my hand in his huge mitt. “So what’s your skillset?”

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Batcopter Boss excused himself while I ran down my list of credentials. Jimmy motioned for me to follow him back out through the door and into yet another office.

In this room two guys were sitting in front of some monitors. They looked pretty young, I had at least ten years on both of them. On a large table against one wall were some drawings for the coffeemaker I’d seen the other guy working on in the model shop. Jimmy started describing where they were in the project and what more needed to be done, quizzing me on various parts of the drawings; I offered input and pointed out something on one of the drawings that I thought would be a problem to mold.

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Underneath the messy stack of drawings was something that didn’t match, and I pulled it up to ask about it. They were drawings for a toy design, another ID area I had experience with. Soon Jimmy and I were talking about that project too. Now here’s the thing: At that point I didn’t have a lot of money, I didn’t have a lot of what I considered professional respect or renown, but I definitely had a shitload of experience. And in that 15 minutes, Jimmy saw it—because next thing I knew, he was asking me how I’d like to head those two projects up. A half an hour ago, he didn’t even know my name.

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