This custom home in Little Compton, Rhode Island is nearing completion with the beautiful millwork details made by our craftsmen at National Millwork in Mansfield. This front portico, over the main entrance to this house (shown above), is probably one of the most challenging things we have done, only because of its sheer size. There are four beams made out of Western Red Cedar, which are 4 inches thick, almost 5 feet in height and 21 feet long. These were glued in the shop, and cut on the CNC machine. Each one had to be run through the planer, then through the sander (several times) before they were completed. It took four guys to lift and move them every time. The beams holding them up were also pretty large, at almost 6 feet by 8 feet when fully assembled. Note the curved gutter above the doorway, and dentil blocks.
The next picture is a perfect example of what we can do. Starting at the top, above the roof line is a widow’s walk that we built for this customer. All PVC 12″ wide hand rail, with matching upeasings and ballusters. Coming down to the roof line, this is one of the curved gutters that we built (like the one we bring to our shows). There were 12 of these in total, all made out of mahogany and fir. These were glued together and then cut out on our 5-axis CNC machine. Also, at the roof line are the PVC brackets that we made to a total of 755 of them! We assembled all of these in the shop, and the backside of each block was made to match the crown moulding, which we supplied.
By doing all of this custom millwork in our shop this way, the contractor estimated that we saved him over one month of labor on the fabrication, and installation side. Plus the fact that every one is identical.
The custom octagon ceiling and coffered ceiling were built by us, including the beadboard and matching trim. These were cut on the CNC machine and assembled in the shop out of poplar. They were then sent out to the job for installation.
We also built 18 PVC pilasters (non-structural columns) and brackets, which were then attached to the columns when installed at the jobsite. This extensive project gave so many opportunities to showcase our capabilities that we look forward to sharing more pictures in the future.
The last photo is of some of the Interior Custom Millwork work we did. This was all made out of poplar, and the columns, and detail blocks were made and assembled in the shop. There were 22 of these columns and block assembles that we made. Also note the curved wall and trim. We made a template of what they wanted, and then we actually made the wall in our shop, which consisted of top and bottom plates and the studs. These were cut on the CNC machine. By doing this we now had the programs to make the radius trim. This really pushed the envelope as to what we could do on the CNC machine because of the height of the trim itself.
What can we do for your customers?