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Fabricating and Installing Colonial-Style Wood Wall Panels

Carpenter Bob Ryley is on location to begin work on a reproduction wood-paneled wall in the project home's formal dining area. The wall panels, which were inspired by a visit to the Winslow Crocker house, a 1790 example of Colonial architecture on Cape Cod,. They will be made from knot-free, select grade pine. After discussing the room's layout and consulting an architectural rendering, Ryley begins to cut, assemble, and dry fit the panel elements. Ryley first mills the vertical trim pieces, called stiles, and the horizontal rails on a router table. Next, a wall panel is milled from three boards which have been glued and clamped overnight. Finally, Bob and Ryley begin to temporarily assemble the panels on the wall. Once all the pieces of the wall panels have been test fit, final assembly can begin.
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Fabricating and Installing Colonial-Style Wood Wall Panels

  computer-generated transcript - may not be 100% accurate

" Authentic colonial homes often had beautifully paneled rooms and we're going to make. I an attempt here -- creating the same look that we saw in one of the historic houses earlier in the series the Winslow Crocker house beams paneling that was in that house had been crafted in the late eighteenth century and much of what's there is intact we aren't -- going to try to reproduce one of the moldings that you see in this wall and this wall was actually stripped of its original paints by the previous owner of the house about 67 years ago which makes -- a little bit less authentic however what we have here will be made out of pine and will be painted and Bob Ryley you're going to show us how you go about crafting this with today's modern tool."

" That's right well the important thing on this wall here is that this fireplace is centered in the in the wrong so we want to be sure that the panels. A senate as well also going to find sent it yet. Establish where this stile in his stile here going that -- its browser of the vertical -- exactly and then the rails would be the hours on horizontal right so what I'm doing right now basically is laying them out so that I know exactly where they're going to go. And to get a height on them to account and once it got all that -- just not fabricating the pieces."

" And let's let's put her on the bench so we have more closely at the individual pieces and how you get them. OK this is C. This is the grooved cut here basically what you're doing is have this bit would sit in here. And that makes that groove into the wood and when that's running there are some basics to keep in mind in terms of the direction of the wood. Basically Daria you want to have this wood here running this -- be the first minority happens as the -- and just run them off -- onetime suspect another bit that you're going to switch over to what you've got all the Stiles cut. Thank you change it fits you know -- this -- and and it's a kind of of the the rail stock for the rail stock exactly. And when you're doing the rail stock. And the style thought you want to do all in unison so you've got all the different pieces that you're going to be requiring a lot of water right."

" In this corner here it isn't personal we want to get up. Everything above this blue line is not going to machine that's Iraq all of this coming."

" Have you pre marked where the studs are located. Not. And that's why I'm actually with the what size nails we use these -- around six penny. Finish nails. Panels involve putting together different boards of different sizes to create the widths that we want to use. To create the design that's going into the room we've got three boards that have been glued and clamped together and then planed down and run through the rounder shape particularly get this beveled edge right but when it goes to the table with -- three passes because we've taken out so much -- We try to put one pass it through the heck out of the way -- the first two passes really taken out most of the way. The final pass -- you're doing is taking up about sixteen and that's what really cleans -- in my shop now Bob you've got. The bottom rail in place right now is this is all dry fitting that we're doing now the whole the whole wall should be dry fit right there right then then we could take it down in and input to -- piece together with a little. -- let's talk about the quality of the wood that we're using here. -- aren't sad native eastern pine and it's that what we'll that is select. -- so it's not for me it doesn't have any knots in it still not so they can stain -- if they had you know that the moisture content is the important thing right exactly -- we're fortunate -- that -- the more -- on -- came -- 9%. Which is ideal for what we wanted to hit the now do you want to put little reusing six penny nails just tacked them in place -- front hall but up and out really just want to make sure earnings benefit when we install for sure you'll be using what eightpenny finish and -- finish and Nelson -- and clamps down."

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