Building a Solo Woodworking Business | Zac Matheou of Lycan Design

In this episode of Yours For The Making, host Robin Johnson sits down with the self-proclaimed “ply guy” - Zac Matheou, founder of Lycan Design, and a master craftsman known for his impeccable plywood cabinetry and honest takes on life as a solo maker.Zach shares the story of his winding path into the world of bespoke joinery - from helping his dad in a pine furniture factory to a special effects career and eventually founding his own workshop. With over 11 years of hands-on experience, Zach opens up about everything from the realities of running a business alone, the beauty of hand-drawn designs, tool brand snobbery, pricing struggles, sustainability, and why he’s still not quite sure how he got here.If you're a cabinetmaker, independent designer, joiner, or creative entrepreneur — especially one trying to balance quality craftsmanship with business growth — this is a masterclass in real-world making.In this episode, you will learn:Why Zac left special effects to build kitchens from scratchHow he built Lycan Design as a one-man, family-first businessWhat it’s really like being a solo maker in a social media worldThe challenges of pricing bespoke work fairlyWhy he refuses to compromise on quality - even at his own expenseHis thoughts on plywood trends, tool snobbery, and the IKEA effectThe future of British joinery and the skills gap crisisHow sustainability and simplicity drive his entire processThis episode is a must-listen for:Woodworkers and furniture makers, independent craftspeople and designers, creative entrepreneurs, Architecture and design studio collaborators, fans of high-quality joinery and British craftsmanship and anyone building a values-led, purpose-driven making businessKey Moments: 0:00 - Introduction to Makers and Craftsmanship0:54 - Meet Robin Johnson and Zac Matheou1:19 - Zac's Plywood Expertise2:09 - 11 Years of Working with Plywood3:03 - Challenges of Running a One-Man Business6:30 - Zac's Family Background in Furniture9:02 - Career Journey in Special Effects10:33 - Workshop Evolution11:36 - Challenges of Workshop Transitions13:07 - Lessons Learned in Craftsmanship15:08 - Attention to Detail in Woodworking22:38 - Relationships with Architects and Designers24:38 - Social Media Trends in Woodworking32:33 - Tools and Technology in Craftsmanship38:30 - Design and Manufacturing Process41:42 - Plywood Supply Challenges48:09 - Waste Reduction and Material Optimisation54:27 - Apprenticeships and Trade Skills1:08:37 - Spray Finishing Techniques1:16:45 - Pricing and Value in Custom Furniture1:22:37 - Advice for Aspiring Craftsmen1:28:25 - Future Plans and Business Goals for Lycan DesignEnjoying the show?Leave a review, follow us, and share the episode with a fellow maker. New episodes every week with artists, designers, craftsmen and creators from around the world.Yours for the Making with Robin Johnson is the podcast that celebrates creativity, craftsmanship, and the art of making. Hosted by Robin Johnson - founder of Johnson Bespoke and BBC presenter on shows such as The Travelling Auctioneers, The Restorers, Woodland Workshop this podcast dives into the stories of makers from all walks of life. From woodworkers, metal fabricators, and chefs to artists, designers, and hobbyists, each episode offers real conversations with the people behind the things we love.Whether you're a hands-on creative, aspiring artisan, or simply curious about how things are made, this podcast offers inspiration, insight, and practical wisdom. Expect behind-the-scenes stories, lessons in process and passion, and a celebration of the maker movement in all its forms. Subscribe now and follow Yours for the Making wherever you listen to your favourite podcasts.