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Porch Restoration: Custom Reproduction Mouldings and Chadsworth Columns

House five of the Elmwood project. Porch restoration continues. Forester Molding re milled many elements of the porch.
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Porch Restoration: Custom Reproduction Mouldings and Chadsworth Columns

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" Work continues on our porch restoration here in the elmwood neighborhood of Providence, Rhode Island. Glenn is sistering on new supports to the ceiling joists. Terry Bates is trimming out the new pressure treated posts for the porch railing. Now that the foundation is finished Georgia Pacific plywood sheathing is applied to the new porch structure. -- the half wall has been reframed and is almost ready for new shingles and a new cap. And the red cedar shingles the has been installed on this particular half wall that you've got here. On the edge of the porch steps don't make a note of what's happened here though because this is a very interesting detail that's the circle we've got here. It's it's really typical of a shingle style house for the flat plane of the shingle side wall to go into occur without any kind of interruption no no moldings no corner boards of any sort and of course when you're doing a full circle like this the only way to do it is to use narrower widths. The red cedar shingles which allow you to build into it. This circular area. And now to cap all of this our friends. And at Forester -- has taken a nice piece of lumber for us solid piece. And put the beautiful groove right into it. The new cap was milled here at Forester moulding and lumber and let mr. Massachusetts. First a template is screwed onto the piece of South American mahogany that'll be milled into the new cap. A piece of the original cap was used to create a profile in high density plastic with a computer aided design program."

" A grinder uses the profile to create a -- for the molder. In a process similar to copying a -- the steel assumes the shape of the profile. The knife is placed into the head of a tilting head molder. The molder can position the knife at any angle. As another quality control check the knife is compared with the original cap before cutting. -- The template guides the piece of wood through the molder so the cutting knife is in the correct position. It takes two passes through the molder to cut the profile into the mahogany. A single pass would remove the excess too quickly and chip this expensive piece of wood. A second pass through the molder creates a very smooth profile. One final quality control check is made against the plastic profile and the piece is finished."

" Now coming up the stairs we've rebuilt the structure as well as the structure of the deck and clad it in mahogany which has been. Put together tightly so that the water won't be getting through it. And right now let's get started with a friend Jeff Davis who is helping us with the columns hey Jeff about are these are Chatsworth. And they are. They're not wooden columns are they --"

" This is actually a polyurethane for the cap section is on the top and -- the same bank president composite marble dust with fiberglass mixture that's very thick. Bob this column right here being it's eight inches in diameter at the bottom would hold about 6000 pounds rated on a pot them safety factor that's amazing there's no steel reinforcing or any dancer the strength dissolve from the fiberglass and the marble dust in the -- and marvelous what makes so much heavier and thicker and makes it more like a column. Okay now if I want to. Get columns like this you can't find him at the home improvement center we wear it direct mail company and you want directly from us through 1800 columns or that we get to that dot columns. 1800 columns yet and that's how you can get it absolutely all right we'll Terry and his friend are already busy already got one in place."

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