Here's a technique professional carpenters use to conceal nails or screws: use wooden plugs. Use a dowel bit to drill out the plugs. Dip each plug in carpenter's glue, and tap it into place over the nail or screw. Let the glue dry, then shear the plug off with a wood chisel. Sand the suface smooth and apply your finish.
Bob takes us on the first of many visits to the Winterthur Garden and Museum in Delaware's Brandywine Valley. Winterthur was the vision of Henry Francis DuPont, who researched and collected antiques and housed them here. Greg Landry, Director of Conservation for Winterthur, takes Bob to the Dominy Workshop, which once belonged to a family of carpenters and clock makers on Long Island. The workshop-turned-museum houses a multitude of Colonial-era tools, many of which are still in use today. Bob takes a turn on the great wheel lathe, which was used to mill large items like table tops as well as other decorative items. Landry also shows Bob some hand tools, including antique saws, planes, and drills.
Bob explains that the house being remodeled was built in 1921 and has never had a real facelift on the exterior. As a consequence, the home's trim, porch ceiling, decking, and windows were all in need of repair. Bob points out the oriel window's exterior frame that has allowed cold air into the home. To fix this problem, local carpenters were called in to tear it apart, insulate, and restructure it. Forester Molding & Lumber was then brought in to replace the 85-year-old trim. Bill Hopkins from Forester Molding & Lumber reviews how old house moldings cannot be found in lumberyards and must be replicated. Hopkins uses a needle gauge to trace the profile of the trim. The needle gauge is then placed on a piece of graph paper and traced. The profile is then used to search for available matches in the Forester catalog. If there is no match, the trim is scanned into the computer and a specialized knife is cut. The knife is then used in the machine to rip the molding.
Bob Ryley installs baseboard molding on the floor of the governor's mansion. Bob Lidle, trim carpentry foreman shows Bob some baseboard trim work involving a baseboard heat register.
Bob checks in on the finish carpenters who are installing wall paneling in the entranceway. They are using a medium density overlay (MDO) and 1/2 inch poplar slats to create the recessed panels. Bob also shows off the finished second floor bathroom tile and the repaired windows.
Robert Adam, an instructor at the North Bennet Street School, provides a look inside one of the facility's workshops where several projects are underway. Work in progress includes a new balustrade for the cupola of a local historic home and new mahogany doors for the school's service entrance.
Bob Ryley installs a chair rail and replaces the glass in the doors of the dining room hutch. Ryley cuts the necessary pieces of railing using a coping saw to achieve an exact fit. Bob then describes the restoration and replication process of the corner cupboard. Danny Ruffini is busy glazing the cabinet doors, using a hot glue gun to secure the glass to the frame. Lastly, hinges are added and the doors are hung.
There's more to nailing than just ready-aim-swing. Face nailing is what we all learn how to do first. Drive the nail straight through one piece into the other. This is the quickest and easiest way but not really the strongest. For added strength try toe-nailing. Drive a pair of nails at opposing forty-five degree angles. This is the method carpenters use to frame a house.
Bob meets up with Tim Colgan to look at the Kahrs white oak flooring being installed in the bedroom. Earlier in the week the carpenters put the oriented strand board (OSB) underlayment down with construction adhesive over the old boards. The flooring installers first put down is their proprietary padding made of Airolin foam beads in between two layers of plastic. The padding provides sound and moisture resistance and additional comfort. There are no nails or glue involved in the installation. The end seams are put together first. Once the board is laid into the previously installed row it's topped with a heavy plastic block. There is no need to use a hammer. The secret to the tightness of the installation is in the interlocking joint � it's completely mechanical. However, some play is built in to accommodate environmental changes. The backside of the product is spruce and the inner core is finger-jointed pine with quarter sawn vertical graining. Because of this all the expansion will be vertical and won't affect the wear layer of the floor. As for durability, Kahrs guarantees two full professional sands of the product. The finish is an acrylic urethane, which is actually harder than polyurethane and is non-yellowing. Eighty percent of the Kahrs line is natural colors � not stained � which eliminates the problem of the lighter natural color of a dark stained wood showing through with scratches and wear. The installed starting price point is about $8.00 a square foot. Because this is a floating floor expansion is left around the perimeter. A special "T" molding is used to join two like heightness floors and give it a finished look.
Bob confers with two carpenters as they begin to install the dutch gable roof system on the back porch. The ridge beam is secured and rafters are added.