Castleman Carpentry (Berryville, VA)
Main Category: Bath
Sub Category: Other
Dollar Amount: Under $25,000
What materials/species were used in this project/item?
This contemporary bathroom was fabricated from Maple hardwood and finished with a clear honey finish. 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.
Describe, in detail, the project/item’s construction.
All cabinetry & millwork was fabricated in our shop in Berryville VA. We fabricated our doors utilizing 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. 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?This small contemporary bathroom is unique in that it was carved out of space from the existing master bedroom and did not previously exist. The homeowner loved their Asian inspired tub & decor. We designed and fabricated this contemporary vanity to float in the space with accent lighting below and above. The river rock feature ties into the shower and floor detail. The most interesting request was the custom drawer insert for our homeowner’s makeup. The makeup drawer was designed with a magnifying mirror to flip up horizontally so our client could apply her makeup while sitting on the vanity stool and easily tuck the makeup and mirror away into the vanity.
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.
Granite was provided by A&S Marble & Granite in Winchester VA. Plumbing fixtures were provided by Signature Hardware. Lighting fixtures were provided by our homeowner and installed by our crew. Tile & river rock was provided by The Tile Shop in Sterling VA and installed by our crew.
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. We have found your publications and website to be both interesting and an excellent resource for us.