Custom Oak Built-In

I recently built a custom oak built-in for a new client. It was both the largest and the finest built-in that I have undertaken to date. This project presented me with many challenges and learning opportunities along the way. Most of the built-ins that I have built have been painted, however this one was solid oak with book case uppers and cabinets with doors for the base cabinets.

I had originally planned to build this unit on site, but after giving it some thought I determined that it would be a better finished product if it were built in my shop and then installed on site. After another meeting with the homeowners to discuss details and take some detailed measurements I was ready to get started.

This built-in is wall-to-wall and floor-to-ceiling measuring 96" tall x 118" wide. I felt that it would look best if we divided the 118" into four sections to give the overall built-in proper proportions.

CONSTRUCTION
I started with the four book case uppers. The first thing I did was create the arch tops. The overall construction was typical cabinet construction except for the bottom of each unit as it did not have a bottom. I dealt with this by adding some temporary bracing to hold everything square and secure.

Next step in my process was to build the base cabinets. Rather than build four base cabinets I built two with a center divider in each giving the look of four cabinets which maintains the proper proportions. Once again the construction of the bases was typical cabinet construction. I also built doors for the base cabinets which isn't the first time I've built cabinet doors but it was the first time building doors of this style. They are a typical frame and panel construction with a Roman Ogee detail. I had to purchase the 2 piece router bit set to accomplish this and was pleased with the overall results. I did, however, learn a few tips and tricks that will be useful in the future.

The top for the base cabinets was solid oak. I used 2) 1x 12x 10' tongue & grooved together with a Roman Ogee edge. I couldn't be happier with how well the top turned out. I hadn't ever routed out a tongue and groove like this before and it turned out great and the top looks beautiful.

The final two pieces to complete the construction was to create the header piece and the crown molding. The header piece was just a 10' piece of 1x4 oak with a Roman Ogee detail and the crown was just a piece of store bought molding.

Each bookcase received 4 shelves and each base cabinet has 1 shelf. All shelving was completely adjustable using shelf pins with pre-drilled holes. I use strips of pegboard to duplicate accurate pre-drilled holes.

LIGHTING
Per the homeowners request I installed lighting in the tops of the bookcases. I picked up some under cabinet puck lights that I recessed into the tops of the bookcases. After final installation the lighting and wires aren't accessible so I made the tops of the bookcase removable in case there are ever any issues. There are 4 lights that are all daisy-chained together and plugged in to an outlet behind the base cabinets. I ran the power supply in between the middle two bookcases and added a switch in the third cabinet from the left so when you enter the room you don't see the switch.

FINISHING
The built-in was finished with a dark stain from Minwax. The homeowners had an old oak desk that they wanted to match so I actually had to pick up a couple different stain colors and create a custom color to get a good match. I'm a fan of polyurethane to seal and protect my projects so I used a Minwax clear satin fast drying polyurethane. I also like to thin my poly with mineral spirits, I feel like it makes for a smoother finish. All of the stain and poly were brushed on since I don't have a spray booth.

INSTALLATION
Installation day always makes me nervous and this install was no different. Although I knew all of my measurements were correct and I had a solid plan for the install I was still nervous. Well as it turns out, I had nothing to be nervous about, the installation went smoothly.
Part of what makes me nervous about the install is the transportation. But, again, this went off without a hitch and all components arrived on site unharmed.

We started by laying out drop clothes to protect the carpet as it was a rainy day. Next I removed the base board trim where the built-in was going. At this point we started installing the base cabinets. Once they were installed I moved on to the top for the cabinets. I made the top a couple inches too long so I could cut the ends to fit once on site. This was probably the one aspect that had me the most nervous, you only get one shot at this and if it's too short you'll have gaps and if your not careful you can damage the walls. Well, I made some careful calculations as to the slight "out of squareness" of the walls and the overall length and went for it. It was a perfect fit and I couldn't have been more relieved.

With the top installed I pre drilled the hole for the electrical and moved on to the bookcases. I started with the far right bookcase and worked my way to the left until all four bookcase were in and secured them all together. Once I had them all secured together I anchored them all to the wall and moved on to the finish trim.

We cut the header piece and crown molding to fit and installed them across the top of the unit. With these installed we moved on to the scribe moldings that were installed to cover up the small gaps on each end. I also had made up some moldings to finish off the seam between each cabinet. I had a hard time deciding whether or not to actually use them so I called in the homeowner and let her make the final decision. She chose to have the moldings installed and I think it was the right choice.

The last step of the installation was to wipe the entire unit down with some Old English furniture polish and install the shelves.

The install took about 5 hours to complete with the help of my step-son Jackson and my father-in-law Duane.

That wraps up this post, this was one of my most rewarding projects. Everything turned out great and the homeowner's expectations were surpassed.

Thanks for reading.
Rex

TOOLS: New vs. used

As the owner of a growing carpentry company it seems like I am continually buying tools. Nearly every project provides the opportunity to add to my tool collection. Well, for the most part that suits me just fine since one of my favorite past-times is buying new tools.

However, new tools aren't always in the budget so over the past few years I have purchased several used items with good results. Of course, I would like to always buy new but when I can't, I have found that research and patience pays off.

My most recent used tool purchase (cordless framing nailer) was only about 1 year old and I was able to pick it up for about half the cost of new. I had been checking them out online, watching prices, etc for a couple months before I came across the one I bought.

I have a few key criteria when looking at pre-owned tools.

The first, as expected, would be price. I don't usually even give a used tool a second look if the price tag is more than half the cost of new.

The second criteria I look at is condition. Regardless of price, if a tool seems to be on its last legs, I don't think it's going to be a good buy. I also insist on being able to test the tool before I buy. At the very least I want to make sure it works and get a feel for the condition. I think you can feel the condition of a tool better than you can see it. Anybody can clean something up and make it look nice but, until you 'test drive' it you don't really know what your dealing with.

Next, I like to consider who owned/used the tool before and how they took care of it. There is no exact formula for this, whether it be a professional contractor or a weekend warrior, you never can predict how a tool was cared for, so I try to ask questions to get a feel for what kind of life the tool might have had.

One last requirement which, for me, is maybe the most important.  I would never buy a used tool 'sight unseen'.  I think you would be asking for trouble to buy a used tool online without being able to see it, feel it, and test it before making a purchase.  If a used tool can meet these requirements; price, condition & test drive, care, and an 'in person' purchase, then I usually feel comfortable about my purchase.

All in all, I think buying used tools can sometimes be the best way to go when you're on a budget like most of us are these days. However, you do kind of miss out on the rush of taking it home from the store and tearing into the box when you get home.

Now if you'll excuse me, I need to get back to the workshop.
Thanks for reading.
Rex

Custom Built-In

This week I've been working on a large custom built-in unit. The term 'Built-In' doesn't really do it justice. More like a built-in bookcase/entertainment center/fireplace mantle/storage unit. This thing is a beast, 8'tall x 9' wide.
If you read my last post you'll know that building something this large poses a few challenges for me. I've had to do a little re-arranging in the shop to make space for it but I'm managing.
I felt it made the most sense to take some careful measurements and build this unit in my shop(where all my tools are) as opposed to loading up my entire shop in the cargo trailer and building it on site. That being said, it was rather nerve racking transporting it all to the location. So, while I still think it made better sense to build it in the shop, the issue of transporting will play a larger role in my decision making process in the future. Everything made it safely to it's final location so, it all worked out in the end.
The built-in is made up of 6 modular units; a base(platform), 2 large base cabinets, 2 bookcases and a mantle piece that spans between the two bookcases. Each component was built to custom specs determined by the height and length of the wall and the sizes of the existing TV and electric fireplace. But the real customization came at the installation. There are only so many details that can be pre-determined, some things need to be accounted for on-site. Aside from accommodating some of the miscellaneous details, I also had to relocate the clients 60" flat screen. 1". It's kind of crazy but it had to be done. So, with the TV relocated and the fireplace set into place it was time to
move forward securing the cabinets. Once all the cabinets were set, it was time to install the shelves in the bookcases, install the base moulding and then, the crown moulding. And that was pretty much it. Final paint touch up was to be done by the homeowner. So, with that I packed up my tools, cleaned up,  took some photos and called it done.

Notable features include:
Doors for storage cabinet
Adjustable shelving
Crown moulding
Black Granite tile Hearth
Customized to fit TV & fireplace

Workshop Set-up

Over this past weekend I spent some time in the workshop cleaning and organizing. My shop was on the verge of being over-run by scraps and sawdust, which is just the way I like it but, sometimes enough is enough. Not only is a messy shop an unsafe workshop, it is also a less productive workshop. So, while I may feel more at home being surrounded by sawdust and woodscraps, I felt it was time to clean up.
For me, doing a little shop cleanup ends up being more of an exercise in re-arranging and organizing my work space. It seems to be this never-ending quest to 'get it just right'.  I guess if you have a large enough workshop with designated areas set-up you may not be constantly trying to re-invent your space. However, I haven't quite gotten to that point. My workshop is in the garage of my home, which I also share with the laundry, workout area, bicycles, and storage. So, after all that, I have about a 10'x16' space to work in.
Most of my tools are on mobile bases, so they can be stored out of the way and rolled out when needed. This is pretty much a necessity in a smaller shop. Being able to roll tools that aren't being used out of the way is probably the only way I can make this small space work.  Having many of my tools on mobile bases goes a long way towards getting the most out of my space but it seems like I am still always struggling to find a good layout. 
I guess the biggest obstacle I have comes back to the limited space that I have.  My workspace is just fine for working on small projects, cutting small materials, making repairs etc.  It is when I go to build something large (like the large built-in I'm getting ready to begin) that I really start itching for more space.  I'll have the shop set up and organized just the way I want it and once the large project begins to take up more and more space I start re-thinking my layout. 
Maybe one of these days I'll come up with the perfect layout or maybe I'll come up with a larger dedicated workshop.  Until then, however, I'll just jump on here and vent.

Apartment Rehab

This Fall we've been working on an old apartment complex in Speedway, IN. This particular complex is under new ownership, and they have decided to do a relatively extensive overhaul of the place. As you can imagine, if you've ever lived in an older apartment, they are in desperate need of some TLC.
Our role in this project is doing the interior finish. We are installing new lighting, window coverings, bathroom accessories, bathroom vanity, closet doors, kitchen countertops, and some units get all new kitchen cabinets. Nothing fancy, mostly low budget inexpensive fixtures, but it's all new and a major improvement.
I haven't done too much work in multi-family residential construction. Most of my experience is single family semi-custom homes. It's a bit of an adjustment working in vacant apartments as opposed to someone's home.
So, while this work isn't too difficult or anything I haven't done before, I got to thinking the other day that it's good practice. We could all use some practice, whether an experienced carpenter or a beginner.
I had this thought the other day, when discussing the project with my crew, one of which has limited experience. It's a fast paced/production style atmosphere and the materials are inexpensive(which means I can let guys get their hands on things that I would normally insist on doing myself).
While this project may not be anything too exciting, nothing fancy, or maybe I won't be getting any cool photos, the one thing my crew and I can take from it is the practice and experience. Both of which are invaluable for any tradesman.

9/27/2011 Remodel

This past week we wrapped up another small remodel project.  This project was mentioned in my 'Long Hours' post.  This was a nice little job close to home and for the most part everything went smoothly. 
I say 'for the most part' because we did have 2 small setbacks. 
As mentioned in the previous post, the homeowners experienced a small delay in taking possession of the property so we lost one day from our original schedule(hence the Long Hours).  All in all, this wasn't too much of a problem. We were still able to finish the job on time and within the original budget. 
Our second setback was tearing up the old flooring.  As with any remodel, sometimes you just never know what you might be getting into.  The carpet came up without a problem, as expected. As for the linoleum in the entry and kitchen, well that was an entirely different story.  5 layers.  1/2" particle board, 2 layers of old linoleum, 1/4"  underlayment, and another layer of linoleum.  It was an absolute bear to remove.  However, we did get it all up and all the floors were stripped down to the bare sub-floor.
With the floors stripped, we installed Durock cement backer in the kitchen and entry.  Followed by the installation of the tile.  Everything was pretty straight forward with the tile installation, just a 13"x13" tile,no angles or fancy patterns. 
Throughout the living room, dining room, and hallway we installed 12mm engineered wood laminate flooring the homeowners purchased from Lumber Liquidators. It was again, a pretty straight-forward installation finished of with the installation of new shoe-molding.
Aside from the flooring we removed a wall separating the kitchen and dining room.  The two rooms still have the same footprint but having the wall gone really opens things up visually. 
One last thing we did was wire in for a ceiling fan in the living room and master bedroom.
Like I said, this was a nice little remodel.  The home-owners are a younger couple who have purchased a nice little home that's just a little outdated and they have a few more projects they plan to tackle down the road.  I have a good feeling we'll be getting a call when the time comes.
Well that's it for now, thanks for reading.
Remodel Photos

Theater Room

Recently I wrapped up a Custom Theater Room Transformation.  The end result was a huge success.  The total project was spread out over the course of three and a half months.  We had some prior, ongoing commitments and the client was saving up the funding as we went along so, in this situation it worked out for all parties. 
The existing space was an unfinished 10'x16' basement room with 4 concrete walls and one door opening.  Per the clients specs/vision, the space was to be transformed using decorative columns, custom woodworking/moldings, an elaborate lighting plan and too many other details to even wrap your mind around.  I'll do my best to explain.

Before we began the client had an HVAC contractor come in and raise the existing duct work so it was less of an obstruction.
One detail that had to be worked out before we began was to figure out who-what-when-where-how we were going to come up with all of the moldings we would need.  The client had some specific, one-of-a-kind capital and base moldings that he wanted produced.  Well we couldn't find them anywhere, nor could we find someone to mill them at a reasonable price.  Having exhausted all other options the client provided me with a disected breakdown of the molding details, so I figured I would give it a try.  Success.  I started by making up a couple sample pieces, we made a few tweaks before production, and the end result speaks for itself.
Our first step was to build the platform for the upper sitting area, we built a bulkhead around the new ductwork, installed 1x4 slats 12"o/c for the ceiling tiles, installed 2x6's around the perimeter as 'beams'. I then installed 2x12's and 2x10's(corners) for all of the columns.  As mentioned, all of the walls were concrete so all of the electrical lines were recessed into the backsides of the columns and beams.  So, at this point, we mapped out all of our electrical, removed all of the columns and beams and routed out tunnels into the backsides of the columns and beams.
The baseboard trim went in next, basically just a 1x8 with a detail routed into the top to match the trim in the rest of the house.  We layed out the louvered lights and cut the holes. 
My next step was to route the fluting into the columns.  This was another 'skill builder' as I had never done this before.  But I knew with careful planning and accurate calculations that I could pull it off.  I started by building a 2 part jig.  One part sat on the column, like a saddle, and the other piece nested into the 'saddle' and was adjustable.  There is much more explaining to do but maybe that should be anothe blog post.
We also had to route out for the rosettes at the tops of the columns, which required another jig.  So, we removed the columns, one at a time, and routed the fluting and rosette recesses and reinstalled each column.
With the electrical buried behind the columns and beams and all of the routing done I patched and filled all of the holes and put a coat of primer on all of the woodwork. 
At this point in the project I was not on site much, we had a family vacation, and I spent a great deal of time in the shop creating the capital and base trim for the columns.  I think, out of all that I did on this project these moldings are what I'm most proud of.  I never imagined that by simply disecting the moldings thta you could make them, piece by piece, laminate it all together and it turn out as good as it did. 
I think that is it for now, I'll pick up where I left off soon.
Thanks for reading.
To see before, during and after photos follow the link below.
http://www.facebook.com/media/set/?set=a.237501969634059.77265.132384660145791