Castleman Carpentry (Berryville, VA)
Main Category: Bookcase
Sub Category: Other
Dollar Amount: Under $25,000
What materials/species were used in this project/item?
This bookcase and fireplace surround was built using solid Maple hardwood, finished with Snow White milk paint, clear semigloss top coat. We constructed our cabinet boxes from 3/4″ Maple Plywood which we purchase prefinished from Hardwoods, Inc. in Frederick MD. At exposed cabinet surfaces we utilize 3/4″. All face frames, drawers, moldings and shelves were fabricated from solid 4/4″ maple in our shop. We used Blumotion undermount full extension drawer slides and Blum European Compact hinges with Blumotion. The countertop was constructed from solid 5/4 Hickory and stained to match the homeowner’s existing Hickory flooring.
Describe, in detail, the project/item’s construction.
All cabinetry & millwork was fabricated in our shop in Berryville VA. We fabricate our doors utilizing two 3-HP spindle shapers as well as a 1.5-HP spindle shaper for coping and joints. We cut panels and lumber to size on a Shop Fox 5-HP 12″ cabinet saw. We mill our own trim on a Shop Fox 7″ Mini-Moulder. Our face frames are constructed with pocket hole joinery which we mill on a Kreg-Forman pocket hole machine and assemble on a Kreg clamp table. Sanding is accomplished utilizing a 24″ double drum sander, 6″ oscillating edge sander, curves are sanded on a 1.5-HP oscillating spindle sander. We also utilize Festool – Random orbit sanders with Festool dust extractors for final sanding. Finishing is accomplished in our on-site, dedicated finishing room. Stains are hand applied. Paints & Tonor Coats as well as top coats are applied using Turbinaire HVLP equipment. All parts are hand buffed before assembly.
What is the most unusual aspect or outstanding characteristic of this entry?
The existing fireplace in this home was outdated and awkward. We removed the dated brick facade and existing low end cabinetry. We designed & fabricated this new custom wall to wall, floor to ceiling cabinetry to incorporate all of the homeowner’s display and storage needs. In the process, we tied the fireplace and bookcase together seamlessly with a more contemporary mantel that emphasized the room’s high ceilings. The chunky nature of the trim worked well with the existing home’s trim. The bookcase and fireplace surround once completed looked as if they had always been there as they should have.
List any items that were outsourced.
All cabinet fabrication & finishing was completed in our shop. All cabinet boxes, face frames, doors & drawer fronts, drawer boxes and trim were fabricated in our shop. All cabinets and trim were installed by us. Our hardwood & plywood was sourced from Hardwoods Incorporated. Cabinetry hardware was sourced from Hardware Distributors.
How being a member of the CMA has benefited you and/or your business.
We have enjoyed being members of the CMA for a few years now. Your Diamond Awards competition has opened up new avenues for us by showcasing some of our projects. We truly look forward to receiving our publications and have made several industry contacts as a result.