An Innovative Custom Interior Carpentry Project…With Video

I am one seriously fortunate guy. Throughout the course of my career, I’ve had the honor of working on some amazing projects. They have ranged the whole spectrum from building custom homes and additions, to jacking an old farm house, to a curved third story deck, to installing an entire showroom worth of high end kitchens and baths, and everything in between. These have all been tremendously rewarding.

But I have to say, the project pictured here, completed several years ago, has been the most fun to date. This is the vision of the homeowner, also a very accomplished woodworker. I got the call from a relative to meet with him to see about helping him clear a hurdle. He had this magnificent vision, and had built and installed the 2 corner cabinets, and hit a bit of a wall. He knew that he wanted to connect the 2 at the top with a soffit and crown molding, connect the 2 at the bottom with a built-in window seat, and the coolest part of all, cut a hole in the floor to allow for a remote controlled telescopic television stand to rise out of the bench seat. He just needed an ounce of additional help to complete this. Count me in! The main reason for wanting the TV to rise out of the window seat- other than the obvious cool factor- was so that the view of the river through the 2 windows behind it would not be obstructed permanently.

We started by formulating a joint game plan to finish the corner cabinets and then move towards tackling the other objectives on the way to reaching the big goal: Hitting that remote button and seeing the flat screen ascend in all it’s glory.

We built the face frames for the cabinets, and he had astutely pre-planned to have the bottom exposed shelf and subsequent nosing line up perfectly with the window sill nosing to tie everything together at that level. It’s funny, he calls himself “Just Ye Olde Homeowner,” but foresight like this makes it crystal clear that he knows exactly what he is doing. We then cut the hole in the floor after planning the particulars of the seat. Of course we had to do some minor re-framing in the basement, but no big deal. We made some raised panels and raised panel doors, and then built the seat to connect the two cabinets.

The last step was to wait until the cabinets and all of the layers of trim had been painted and cleaned up, before installing the hardware.  We were like a couple of little kids waiting ’til mom and dad got their cups of coffee before we could rocket down the stairs to see if Santa came. Finally, the day came. And what a memorable day it was. We had BOTH gotten Red Rider BB guns!!! The only caveat: He gets to keep his Red Rider, while mine simply morphed into a memory and a goal. I think the greatest part, though, is listening to him explain how this project has changed the way they use the home. It seems that the library has lost it’s use as a media center and now serves as a cozy retreat to read by the fire. How can you beat that?

 

By John Bradshaw

Tackle Custom Interior Trim Carpentry in the Winter or Summer?

Our clients have been asking regularly about whether we also do interior work. This tells me it’s time to write a blog post about interior trim work to provide a small sampling of what we can do.

This is an example of woodworking with poplar we did several years ago, during the winter. It has stayed tight with no cracking or bulging. No need to keep caulking and repainting. The “white” lines you see on the crown molding joints are glare from the camera flash.

We’re passionate about all carpentry. To date, our blog posts have been entirely about exterior projects because we feel that sealing water out of the building is job #1. So, when you no longer have water vulnerability, well heck yes we should talk about your interior wish list.

If you’re thinking about moving forward on a custom trim carpentry project, displaying an exquisite vision that showcases magnificently honed carpentry skills is likely one of your goals. That makes perfect sense. And if we’re going to bring your vision to fruition, we’ll want to ensure that it looks and functions flawlessly for a long time to come.

That brings me to the part where we talk about what conditions are ideal for an enduring and beautiful product. First, let’s get the wood species out of the way. If you want a stained product, then choose the species you like. If you want a painted product, then we’ll be selecting poplar to work with, along with cabinet grade plywood and possibly other accessory products. We choose poplar because of it’s availability and affordability. More importantly, we choose poplar because of it’s stability, strength, and straight and smooth grain. Commercially available poplar is not ever suitable for exterior projects in New England though, it turns black and rots easily. But, it’s phenomenal for interior painted woodworking.

Next, wood is hygroscopic, it absorbs or desorbs moisture in effort to reach equilibrium with the relatively humidity. If your home does not have humidity controls here in New England, then we need to understand what the wood is going to do in the future, in response to the relative humidity changes of it’s environment (the home). Barring humidity controls, wood expands as relative humidity rises in the summer, and shrinks when relative humidity drops in the winter. Don’t think that you can fight the “hydraulics” of it, you can’t. You could slow the absorption or desorption by sealing all sides before installing, but this only slows the process. Alright, that’s enough of the technical mumbo jumbo for now…I’m giving myself a headache. Most importantly, proceed with your trim project when the wood’s moisture content and humidity conditions are ideal.

So, as far as ideal conditions, do we want to be building these things during the winter or the summer? Long story short, winter…conscientiously. The wood has already shrunk, in large part, and will not be continuing to shrink. Therefore, you cut, glue, nail and paint the trim during the winter; then, it’s only going to get tighter in the summer. This can be terrific, unless overdone. The wider the boards are, the more they will shrink or expand. If you have boards that are too wide and too dry, they will buckle or cause other components to buckle when they expand in the summer.

Look at this photo. I believe that this trim was installed during the moist summer months, shrank during the dry winter months and exposed a gap at the mitered joint. The gap was filled with caulking and repainted during the winter months when the wood was still contracted. Then, the wood expanded again during the summer months, squeezing the caulking back out of the joint.

How can we help this joint at this point? I don’t know, Bobby-Jo. I suppose I would probably use a better grade of adhesive caulking that stays pliable. I would apply it during the fall, maybe October when the drying has begun. Essentially, shoot for the halfway point between it’s max expansion and max contraction. Then, paint it. You could expect it to be squeezed during the wet summer, but hopefully just form a slight bulge in the paint, and then subside again in the winter, while remaining bonded. The key here is to not use a hard, unflexible product. This would pop out when squeezed during the wet summer months, every time. Hmmm. It’s October now. I think I’ll ask this customer if I may try this experiment and monitor and report back after several changes of seasons.

To wrap it all up, for the sake of your project, please choose to do your custom interior woodworking project in the winter, to ensure tight joinery all year round. For the sake of your wallet also, you’ll want to tackle this during the winter. Why? Well, you may have an opportunity to save a little bit of dough by offering a New England craftsman an interior project to keep him or herself warm during the bitter winter cold. Most elite craftsman are in a minority these days, keeping them in demand year round, but you may have just enough luck to find one looking to fill a winter time slot. Cheers to moving forward with your vision!

 

By John Bradshaw