High-End Architectural Millwork

18. April 2018 13:38

By: Brent Hull, Hull Historical

As we continue into 2018, I want to encourage you to continue to strive for quality and beauty. I was in the shop the other day to check in on the progress of our current projects and found something that really made me proud of my guys. It was a solution to a door construction issue that no one will ever see, but could have been very ugly if they hadn’t fixed it.

Here’s what they did.

Background: Five years ago, we decided that every exterior door built would be made with stave cores parts. A stave core means the inside of the door is made up of smaller glued together parts. These parts make the door more stable.

We want everything that comes out of our shop to last at least 100 years and we think this type of construction is a superior method. It insures that our doors won’t twist and warp. Best of all, there is great historic precedent for this construction method. We have found in our restoration work that the highest quality doors from the late 1890’s into the 1930’s were made this way.

The challenge for this project was that we are building these doors out of quarter-sawn white oak. When the profile was cut into the stile our thick veneer was clearly visible on the edge illustrated by the sketch below.

However, our craftsmen realized the solution was to insert a wedge of quarter-sawn lumber into the edge so that it hides the joint, but also still appeared to be quarter-sawn on both sides.

I think this is a great example of a passion for craft. This passion drives us to build better and build more beautifully. I’m sure there are other great solutions for this issue. If you have any let me know.


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