I was called to trim out the arched door way. The original doorway was 2 1/2 " from top of doorway to ceiling. I asked the contractor how we are suppost to put a door casing and crown at the top with only 2 1/2". I ended up having to lower the doorway a small amout but still did not have enough room for both. The home owner did not want the doorway any lower. So this was my solution.
DW
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can i play stupid, and ask how that concave molding is made?...i see it a lot...but still am a bit unsure at the different methods..shaper?It really is a beautiful structure...i love it.
Caleb,
The rails and styles are made with flexable 3/8" plywood bent around the contour of the hallway. On the upper moldings we used a rubber molding by flextrim. About $10.50/ft. On the lower side of the hallway we made the molding to match. We had a knife made to use in our Williams and Hussey molder. Saved alot of money by making our own molding. Customer paid for the knife. The molding will bend into the shape you need it. Heating it helps. Caulk it in and paint. Getting the perfect shape of the barrel is alittle more complex though. We spun two circles on the bandsaw and bent the flexable plywood over the circles to make a form. After the form was made we took curfcore plywood with a 1/16" birch veneer and bent it over the form, rolled titebond 2 glue over back side of plywood and bent another sheet of bendable 3/8" ply. over the curfcore and put band clamps around it to pull everything tight and let it set up. The next day we took off the band clamps and you have a perfecly round top of the barrel.
Attached it and used 3/4 mdf for the side walls, then applied the R&Styles and moldings. We charged 4k for the hall. Not sure if that is high or low. Took about week and half from start to finish.
Thanks,
DW
top damn notch,my friend!!
Simply superb work! Congratulations on a job well done.
Nice work!
Thanks for posting your fee, I think this helps woodworkers to have perspective for pricing their time/materials. I don't think I'd do it for much less.
Thanks.
I Done one similar to this in Genuine Mahogany with 1/4" ply for panels, Laminated the stiles and rails and made the pm-5 mldg on a williams-hussey. http://www.woodweb.com/galleries/project/posts/460.html Arch trim also on w-h. You did a good job with flex from what I can see from pics. I have to nail flex too much to hold it in place. Love to see trim carpenter's take on a challange.
Any way I can get a sense of what the profile of that rubber moulding?
Nice Job, I am working on something similar, nice to read about the materials you used, I have some ideas of my own.
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