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
Saturday, October 22, 2011
Thursday, October 13, 2011
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.
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.
Sunday, October 9, 2011
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.
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.
Wednesday, October 5, 2011
Difficult Decisions
Well, seems like I have quite a bit on my mind for this post but I'm not even really sure where to begin.
I guess I'll start by saying that I have recently (this week) made a big change in the path I am taking my carpentry business. For the past 5-1/2 years I have been doing work as an independent installation contractor, installing displays in retail. We did work for a wide variety of clients who I will leave nameless. Basically we would get contracted by 3 entities; retailers, brands, and fixture manufacturers. For the first three years I did this work it was relatively steady and profitable but for the last couple years the volume of work just hasn't been there. I think most if not all of this change is due to the economy. As 'third-party' installers our role in the retail world is one of the first things to go. I believe that many companies, in an effort to save money, choose to do the work themselves. Or, find some other, more affordable option(s).
As another twist, I became a husband in April of 2010 and a father this past May. Having a family has dramatically changed how I view a job with unpredictable hours, random travel, and an unstable income.
In 2009 when things really began to take a turn for the worst, I started my own business, 'Carpentry Plus'. In the beginning it was pretty slow, but I guess that's to be expected. However, since those first few months, work has steadily been increasing to the point where I have chosen to apply myself 100% to providing quality carpentry services throughout central Indiana.
It hasn't been an easy decision, as this is something I have thought long and hard about for several months now. As my business has been growing, it has been nice to have a safety net to fall back on, to fill in my down times. At this point though, there has been a shift in the balance of where my work is coming from. My business has nearly grown to the point where it is now providing me with full time work and an adequate income for my family.
Of course, there is much more that went into my decision making process but ultimately, the dramatic shift in the balance of the source of income has put me where I am today.
This has been a difficult decision for me to make as I have thought long and hard on it for months now. But, in the end, it was a no-brainer. I believe that by giving my business everything I have, it will continue to grow and be profitable.
Thanks for reading.
I guess I'll start by saying that I have recently (this week) made a big change in the path I am taking my carpentry business. For the past 5-1/2 years I have been doing work as an independent installation contractor, installing displays in retail. We did work for a wide variety of clients who I will leave nameless. Basically we would get contracted by 3 entities; retailers, brands, and fixture manufacturers. For the first three years I did this work it was relatively steady and profitable but for the last couple years the volume of work just hasn't been there. I think most if not all of this change is due to the economy. As 'third-party' installers our role in the retail world is one of the first things to go. I believe that many companies, in an effort to save money, choose to do the work themselves. Or, find some other, more affordable option(s).
As another twist, I became a husband in April of 2010 and a father this past May. Having a family has dramatically changed how I view a job with unpredictable hours, random travel, and an unstable income.
In 2009 when things really began to take a turn for the worst, I started my own business, 'Carpentry Plus'. In the beginning it was pretty slow, but I guess that's to be expected. However, since those first few months, work has steadily been increasing to the point where I have chosen to apply myself 100% to providing quality carpentry services throughout central Indiana.
It hasn't been an easy decision, as this is something I have thought long and hard about for several months now. As my business has been growing, it has been nice to have a safety net to fall back on, to fill in my down times. At this point though, there has been a shift in the balance of where my work is coming from. My business has nearly grown to the point where it is now providing me with full time work and an adequate income for my family.
Of course, there is much more that went into my decision making process but ultimately, the dramatic shift in the balance of the source of income has put me where I am today.
This has been a difficult decision for me to make as I have thought long and hard on it for months now. But, in the end, it was a no-brainer. I believe that by giving my business everything I have, it will continue to grow and be profitable.
Thanks for reading.
Friday, September 30, 2011
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
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
Sunday, September 25, 2011
Long Hours
Lately we've been working long hours on our latest renovation. It's not a big project but, due to delays with the homeowners getting the keys and having another project we need to get to, we're putting in the overtime.
So far, we've demo'd the wall separating the kitchen and dining room, tore up ALL of the flooring on the main level, installed cement backer board, 200 sq. ft. of tile and about 450 sq. ft. of 12mm Brazilian engineered wood laminate flooring. At this point, we're about 90% complete and it feels good knowing that this project is nearing an end. Good news is, the homeowners have additional projects to tackle down the road and I've got a good feeling that I'll be getting a call back.
As for the long hours, like anything, there's pros and cons that go along with it. It seems to me that there is an increase in the daily productivity. Obviously, if your working longer you'll get more done but I think it's more than that. I feel like I get into a groove or a zone and if I stay 'in it' and keep working rather than stopping to pickup tools just to drag them back out the next day. So basically, I guess the longer hours give you more productivity and less set-up and breakdown each day.
Another positive to the longer hours is it kinda makes me feel good. At the end of the day, I feel good knowing that my clients are getting their money's worth. There's something therapeutic about a good, long, hard days work.
For me, the biggest down side to the long hours is my time away from my family. I would really like to spend more time at home but I know that I'm earning a living for my family, and that feels good. I just wish there was a way to 'bank' the home/family time from the slower times, but that's life I guess.
And then there is the obvious fatigue that comes with a longer work day. I love what I do, I like working with my hands, being creative, solving problems etc. But, sometimes I feel like I'm wearing myself out.
All in all, I would rather work long hours than not have any work at all, and to me the pros far out-weigh the cons.
So...I'll be back at it tomorrow.
Thanks for reading.
Rex
So far, we've demo'd the wall separating the kitchen and dining room, tore up ALL of the flooring on the main level, installed cement backer board, 200 sq. ft. of tile and about 450 sq. ft. of 12mm Brazilian engineered wood laminate flooring. At this point, we're about 90% complete and it feels good knowing that this project is nearing an end. Good news is, the homeowners have additional projects to tackle down the road and I've got a good feeling that I'll be getting a call back.
As for the long hours, like anything, there's pros and cons that go along with it. It seems to me that there is an increase in the daily productivity. Obviously, if your working longer you'll get more done but I think it's more than that. I feel like I get into a groove or a zone and if I stay 'in it' and keep working rather than stopping to pickup tools just to drag them back out the next day. So basically, I guess the longer hours give you more productivity and less set-up and breakdown each day.
Another positive to the longer hours is it kinda makes me feel good. At the end of the day, I feel good knowing that my clients are getting their money's worth. There's something therapeutic about a good, long, hard days work.
For me, the biggest down side to the long hours is my time away from my family. I would really like to spend more time at home but I know that I'm earning a living for my family, and that feels good. I just wish there was a way to 'bank' the home/family time from the slower times, but that's life I guess.
And then there is the obvious fatigue that comes with a longer work day. I love what I do, I like working with my hands, being creative, solving problems etc. But, sometimes I feel like I'm wearing myself out.
All in all, I would rather work long hours than not have any work at all, and to me the pros far out-weigh the cons.
So...I'll be back at it tomorrow.
Thanks for reading.
Rex
Wednesday, September 21, 2011
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
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
Subscribe to:
Posts (Atom)