To
match the
original
work, in
cases where
the originals
are either
missing
or too
far gone
to save,
and the
pieces
are not
readily
available
at nearby
lumber
supply
outlets,
we've had
to reproduce
assorted
pieces
of cornice,
door and
window
trim, Gingerbread
trim, finials,
columns,
balustrades,
and other
decorative
wooden
items to
match the
original
work.
The
photos below
show the
procedure
for making
replacement
newel posts.
Click on
the thumbnail
images
below for
the full
size photos.
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Hardwood
boards
are glued up
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Rough
shape
is
cut
out on a band saw
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Large
blank
is
placed
in
the
lathe
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We
can
authentically
duplicate
any
piece
of
wood
trim
or
accessory
as
needed,
taking
special
care
in
accurarate
measurements
and
wood
species.
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Posts
can
be
straight
tapered as needed
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Finished
post
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The
sequence
below shows
the steps
involved
in replacing
ball finials
for the
newel posts.
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Hardwood
blocks
are
planed and glued up
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A
cylinder
shape
is
first
formed on the wood lathe
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Finials
are
then
shaped
to
specs
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Play
it
again
Sam
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Finials
are
secured
to
posts
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When
everything
comes
together
the detail makes the difference.
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The
sequence
below shows
the steps
in making
new post
bases.
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Redwood
or
Cedar
blocks
are glued and cut to length
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The
centers
are
found
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Rough
shape
is
cut
out on a bandsaw
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Blanks
are
placed
in
the
lathe
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Final
shape
is
formed
and sanded to specs
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Bases
are
then
secured to posts
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Below:
Manufacturing
new replacement
corbels
from scratch
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Blanks
are rough cut to shape on a band
saw, then a router is used to
form the final shape as guided
by the attached template.
The
inside open work is done on a
jig saw which creates the intricate
detailing.
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Below:
John is working on some
of the
porch detailing for the
Stroud
project.
   
Below:
Manufacturing
new windows
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We
use
hardwoods
that
were
salvaged
from
the same type of structures that we restore.
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A
few
passes
over
the
joiner/planer assures trueness.
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Resawing
boards
on the bandsaw
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Clean,
well-
seasoned stock
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Styles
and
rails
are
cut for the project
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We
use
mortise
and
tennon
joints
for
integrity
and
authenticity.
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Our
speciaty
is
repairing
or
reproducing
unusual
shapes
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We
employ old school carpentry skills
and pride ourselves on careful
attention to detail.
   
These
photos show
how tapered columns are individually
handmade.
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Columns
are manufactured
much the same way as
newel posts, except the
scale is much larger. We have
the capacity and the right
power equipment to do the
work correctly.
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After the
degree of angle has
been determined, calipers
are used to assure the
taper is precisely turned.
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