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.
|
|
|
Hardwood
boards
are glued
up |
Rough
shape
is cut
out on a band saw |
Large
blank
is placed
in the
lathe |
|
|
We
can authentically
duplicate
any piece
of wood
trim
or accessory
as needed,
taking
special
care
in accurarate
measurements
and wood
species. |
Posts
can be
straight
tapered
as needed |
Finished
post |
   
The
sequence
below shows
the steps involved
in replacing
ball finials
for the newel
posts.
|
|
|
Hardwood
blocks
are
planed
and glued
up |
A
cylinder
shape is
first
formed
on the
wood
lathe |
Finials
are then
shaped to
specs |
|
|
|
Play
it again
Sam |
Finials
are secured
to posts |
When everything
comes together
the detail
makes the
difference. |
   
The
sequence
below shows
the steps in
making new
post bases.
|
|
|
Redwood
or Cedar
blocks
are glued
and cut
to length |
The
centers
are found |
Rough
shape is
cut
out on
a bandsaw |
|
|
|
Blanks
are placed
in the
lathe |
Final
shape is
formed
and sanded
to specs |
Bases
are then
secured
to posts |
   
Below:
Manufacturing
new replacement
corbels from
scratch
|
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.
|
|
|
|
   
Below:
John
is
working
on
some
of
the
porch
detailing
for
the
Stroud project.
   
Below:
Manufacturing
new windows
|
|
We
use
hardwoods
that
were
salvaged
from
the same
type
of structures
that
we restore. |
A
few passes
over
the
joiner/planer
assures
trueness. |
|
|
|
Resawing
boards
on the
bandsaw |
Clean,
well-
seasoned
stock |
Styles
and rails
are
cut
for the
project |
|
|
|
We
use mortise
and tennon
joints
for
integrity
and authenticity. |
Our speciaty
is repairing
or reproducing
unusual
shapes |
|
|
|
We
employ
old school
carpentry
skills
and
pride
ourselves
on careful
attention
to detail.
   
These
photos show
how
tapered
columns
are
individually
handmade.
|
|
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. |
|
|
After
the
degree of angle
has
been determined, calipers are used to assure the
taper
is
precisely
turned. |
|
|