Thomas Bump of Fine Custom Cabinetry shows Bob the Maple and hardwood panel cabinets that were built specifically for the Brownstone kitchen. The floor-to-ceiling cabinets were built in the shop, then disassembled for finishing and transported to the site for installation. The cabinets are constructed with Maple interiors and mixed hardwoods for the face frames and frame. The panel is medium-density fiberboard (MDF). The door hinges are concealed inside the cabinet and have three-way adjusting screws so that the door can be shifted up or down, right or left, in or out, to hang the door level and plumb. The cabinets have been spray painted with a lacquer finish that is tinted then catalyzed for a durable, easy-to-clean finish. Bump then shows Bob how the panels are made using puck holes predrilled on the back of the panel that are filled with adhesive so that it can sit in the frame without being pushed proud by a thick layer of adhesive. A small dab of hot glue holds the face of the panel in place. Bump then shows Bob the drawers that are solid Maple on the sides, front, and back, with a Maple veneer on the inside. They feature dovetail joinery and concealed tracks underneath that have a quick release and self-locking mechanism. These drawers are also self-closing.

Nick Beasley shows Bob the custom poplar and MDF (medium-density fiberboard) panels he has made for the tub wall in his new master bath. He installs the panel, which has already been scribed for a tight fit. He tacks the panel in place for now, waiting until the Corian tub surround is installed to make the final installation. The tub is already in place, a Porcher cast-iron model from American Standard. There will be a Corian tub deck and top shelf installed, and a new toilet once the bathroom is complete.

John Martin from WarmZone is on hand to show Bob how the medium density fiberboard (MDF) faced with reflective aluminum shielding and precut channels for the Pex hot-water tubing comes together to create a layout for the in-floor radiant heat system. One key advantage to radiant heat is the comfort level, since it is steady heat that is evenly distributed and free from the blowing, particulate matter that can come with forced-air systems. Martin explains how the WarmZone system comes ready-to-install with complete layout diagrams and directions that make it simple for do-it-yourselfers. The panels are set in adhesive, with spacers to temporarily align them and line up the tube channels until the panels are nailed in place. The heat panels then become the substrate for finish floor coverings. Unlike gypcrete, which is a skim-coat concrete application, these panels add very little weight to the floor. Since it is a 5/8-inch product, there is also no need to alter existing door openings. WarmZone specifies a 3/8-inch Pex tubing to deliver the heated water. Martin fits and taps the tubes in place in the channels to complete the installation. Bob then looks at the heat distribution system with supply and return pipes that come directly from the boiler room below. WarmZone has specified three short runs and circuits, which will give steady even heat throughout the space even with the heat loss calculations they have figured. Michael Willburn from WarmZone shows Bob the preassembled boiler-room manifold board and radiant-zone board that are created match the application and arrive ready-to-install from WarmZone. WarmZone takes the information directly from the homeowner, creates the system to fit the job, and then ships it to the site. The homeowner or installer can do all the work without the aid of a plumber until the system is connected to the boiler, at which point a professional installer should verify the connections and operation of the system before firing it up. Initial costs are about double the cost of a traditional baseboard-heat installation, but the operational savings are approximately 30 percent annually.

Bob meets Jason Hill from New England Classic as their ready-measured and pre-cut paneling system is installed in the Manhattan Brownstone. This flat-panel classic American design is modeled after the Arts and Craft style made popular in the late 1800s. This paneling is made of medium-density fiberboard (MDF) faced with a wood veneer. New England Classic offers Oak, Maple, Cherry, paint-grade wood, or a variety of standard finishes. The entire system is designed as a kit of parts that is custom fitted to the customer's space and style. Customers can go the the Web site and download design forms that gather the measurements and product specifics for the job. An in-house design team then creates a design, an installation plan, and a materials list. Once on-site the system is easy to assemble. First the center of the room is determined and marked, then the baseboard is set and leveled. The first panel is then centered on the line marking the center of the room. Panel adhesive is used on the back of each 3/8-inch panel to hold it in place and keep it off the wall enough to push it into the slot of the rabetted stile. The panel is then tapped into place and check for level. A top rail is slash cut along the edge before being installed with adhesive and nailed in place along the bead. A top cap completes the installation, and gives this panel a true 1890s feel.

Carpenter Bob Ryley and Jim Daniels of Woodport Interior Doors join Bob on location to hang a new door in the master bathroom. The pre-hung, six-panel door being installed is made from medium density fiberboard, an engineered lumber product made from wood chips. The chips are compressed to create a sturdy, stable product that is easy to paint.

In the master bedroom, Bob Ryley is installing the medium density fiberboard baseboard trim. Where two pieces of trim meet in a corner, Ryley's approach is to cope the inside corner. He begins by using a table saw to cut out the majority of the wood. Then, using a coping saw, he follows the trim's edge profile to get a tight-fitting joint. Ryley first dry fits the coped joint to check the work and, once satisfied, secures the trim with finish nails.

Using a jig is a great way to make accurate, angled cuts.

Moving to the baby's room, Bob continues to talk with Bernadette Upton of Eco-Decor about the materials used in an ideal room for baby. Although the room is designed for infants, Upton reviews safety procedures to put in place when the baby becomes a toddler, such as removing tablecloths, anchoring furniture, removing climbable furniture, and safeguarding electrical outlets. Upton reviews Treatment-free fabrics used in the window treatments, including washable cotton and solid wood to avoid the glues and formaldehyde found in pressed woods and particle board. The exposed edges and surfaces of particle board and pressboard should be completely sealed with a non-toxic sealer to stop off-gassing. The sofa is an eight-way hand-tie, which can only be constructed using solid, formaldehyde-free, wood. Upton recommends using wallpaper over vinyl, using a minimal amount of it, and airing it befor hanging. When selecting a crib, Upton recommends selecting one from after 1991 because the crib bars are a safe distance apart from one another and harmful chemicals were banned from the manufacture of children's furniture after that date. The baby's mattress is an organic, chemical-free mattress. The house has natural wood floors with throw rugs. The Baby's Breath brochure is available from the American Lung Association.

Bob shows the Woodport medium-density fiberboard doors selected for the Manhattan Brownstone. They are historically accurate five-panel doors like those made popular in the 1890s. The fifth panel is actually a horizontal in the middle of the door. These doors are paint-grade and will accept a nice painted finish.

Now that the WarmZone radiant-floor heat has been installed, it's time to put the finish flooring on. The homeowners selected a Bellawood white oak, tongue-and-groove floor with an oxidized finish for a 50-year guarantee. Since the flooring will be nailed over the hyrdronic heat tubing, it is critical to avoid puncturing the tubes. General contractor Tim Berky is installing the flooring perpendicular to the tubing, which allows him to see the Pex at all times and avoid nailing into it. Berky shows Bob how he began the installation with the second course cut to receive the supply and return pipes and sited half way over the first loop, which initially runs parallel to the wall and is hidden from view. By starting his courses this way, he can set the power-assist nailer to drive the two-inch galvanized staples at an angle just above the tongue without fear of puncturing the tubing. While Berky shoots the staples, Bob points out how the entire floor and substrate is effectively a green application since it is all wood, which is a renewable resource. The advantage, he says, is that trees are planted every time the resource is used, resulting in increased planting and forest protection. The wood floor will cover the entire space, even under the cabinetry and appliances, to create an even floor and provide full finish flooring should the homeowners wish to remodel in the future.