Castleman Carpentry (Berryville, VA)
Main Category: Kitchen
Sub Category: Face Frame
Dollar Amount: Over $25,000
Briefly describe your business and the type of products manufactured.
We are a small General Contractor that specializes in custom Kitchen & Bathroom renovations featuring our hand crafted Cabinetry. We design, fabricate, finish, and install all of our woodwork. Our projects also include, Entertainment Centers, Library Units, Custom Closets, Fireplace Treatments as well as Custom Trim detailing.
What materials/species were used in this project/item?
Wood species used was locally sourced American Walnut which we jointed and planed from rough lumber in our shop. We construct our cabinet boxes from 3/4″ Maple Plywood which we purchase prefinished from Hardwoods, Inc. in Frederick MD. Our cabinet backs are 1/4″ Maple Plywood, also prefinished. At exposed cabinet surfaces we utilize 3/4″ and 1/4″ Walnut Veneer plywood for case construction as well as skins. We use efficient LED in cabinet, under cabinet and toe kick lighting sourced from Hardware Distributors Limited. We use Blumotion undermount full extension drawer slides and Blum European Compact hinges with Blumotion. We install various cabinet inserts provided by Rev-a-Shelf to include, spice pull out, waste & recycling bins, dog food pull out bin, adjustable drawer peg divider systems. We use General Finishes wood stains and Enduro water based Polyurethane top coats. All stains are hand applies, top coats are sprayed using HVLP equipment.
Describe, in detail, the project/item’s construction.
The lumber was supplied to us by our customer in kiln dried rough form with no straight edges. We milled the American Walnut utilizing a 6″ long bed joiner and a 15″ planer equipped with a spiral cutter head. 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. 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?
Utilizing lumber that had been stored away in a barn for 15 plus years posed it’s own challenge. There are several interesting characteristics for this kitchen remodel including the installation of two cabinet depth sub-zero refrigerators – fully integrated into the cabinetry, custom large – arched range hood, fitting in the wide variety of storage elements required by the homeowner, the custom arch millwork at an existing window to integrate window with cabinetry and the interesting display created from the toe kick lighting. The most outstanding feature of this kitchen is what we fondly refer to as the “continent”. It is an exceptionally large island 14′ x 8′ —L-shaped island, highly detailed and complete with a custom raised Walnut Bar Top, again fabricated & finished in our shop.
List any items that were outsourced (not produced by you or your shop).
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. Granite countertops were provided by A&S Marble Granite, Inc in Winchester, VA. The Walnut countertop was fabricated in our shop and installed by us. Plumbing fixtures were provided by Danze, Inc. Marble backsplash was provided by Mosaic Tile, Chantilly VA and installed by our crew.
Please offer a brief explanation of how being a member of the CMA has benefited you and/or your business.
As a new member of CMA, we are excited by all the various benefits offered.
As a small shop in a rural area, it has been difficult to reach out to other wood workers and stay up to date on all the latest industry tools and techniques. We have already developed contacts and found new sources of blades and tooling just through the Woodshop News magazine. We have been a successful Remodeling/Woodworking shop for 10 years in Clarke County, VA. We have always had a passion for woodworking, but sometimes felt it difficult to separate our love for woodworking with our need to produce a profit. Through the information provided in your magazine and forums, we feel confident that we can continue to do the woodworking we love as well as keep our business viable and sustainable for years to come.