Castleman Carpentry (Berryville, VA)
Main Category: Kitchen
Sub Category: Face Frame
Dollar Amount: Over $25,000
What materials/species were used in this project/item?
For this kitchen we used solid Maple hardwood, finished with a snow white milk paint & custom gray glaze. We constructed 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″ Maple plywood for case construction as well as skins. All face frames, drawers, moldings and shelves were fabricated from solid 3/4″ maple in our shop. We used efficient cool LED interior and under cabinet lighting sourced from Hardware Distributors Limited. We used 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 as well as our own custom drawer inserts as requested by the homeowner. In addition to the painted perimeter cabinetry, we used General Finishes wood stain on the island and Enduro water based Polyurethane top coats throughout. All stains & glazes were hand applied, paints, tonor coats and top coats were sprayed using HVLP equipment.
Describe, in detail, the project/item’s construction.
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 & Glazes 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?
This was a remarkable kitchen transformation. The existing kitchen & eat-in area were divided by a half wall – leaving the impression of a small standard kitchen which happened to have a fairly large walkway between the kitchen and dining area. Removing the interior load bearing wall and masking the necessary beam with millwork to coordinate with the kitchen opened up the space, creating a uniquely beautiful and functional kitchen. The homeowner wanted a traditional kitchen that would stand the test of time without compromising in elegance or utility. We incorporated classic detailing throughout including the toekick cutouts, subtle pilasters & built-in window seat that all add a certain elegance to the kitchen. Enlarging the kitchen also provided separate spaces for the homeowner’s workstation as well as a built-in beverage center complete with ice maker in the eat-in area adjacent to the homeowner’s screened in porch.
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. Granite countertops were provided by A&S Marble Granite, Inc in Winchester, VA. Flooring was provided by Armstrong flooring. Plumbing fixtures were provided by Danze, Inc. Tiled backsplash was provided by The Tileshop, 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 truly look forward to receiving our publications and have made several industry contacts as a result. Your articles are insightful, informative and even entertaining.