two chestnut cabinets

we finished one up yesterday that we've been working on for a while. it was good to wrap it up since we first started with our design work back in april. there were delays along the way while the stone was changed on the fireplace, which added to my work and required some additional site visits, but all in all, they look about the way i imagined them in my photoshop paste up below ... click the photos to enlarge them ...
here's the 'before' shot. the clients purchased this house last winter and remodeling started in earnest in the early spring ... sam made about 65 feet of new steel and wood railings for the stairs and the balcony; we made an expanding pedestal table in chestnut, and this pair of cabinets. nice job ....
here's my photoshopped mockup using a picture of a cabinet we built back in 2002 ...
the cad drawing showing the interiors of the cabinetsone of our first design issues was accommodating a tv that was wider than the space between the retracting doors. we made a couple of mockups using our standard sanus bracket, with different ways of mounting the bracket and decided on the 'sidewall' approach, which worked fine ...
we also had some fitting issues as the client requested that both cabinets be identical in width. after they changed the stone on the fireplace, that increased the width of the space and thus the cabinets, and brought a twisted spruce beam into play that was previously not an issue.
the tops and molding backer boards actually slid into a slot created in the masonry
we also had to revise our installation plan from a grouted board against the existing stone to a 'slot' created by the masons when they reset the facing. that made me define my spaces pretty exactly and while it was fussier to install made for an elegant look of the cabinets integrating into the whole fireplace surround ... looks greatwhile we were checking the twisted post, we also mocked up a paneled end, which is what you see when you come down the stairs.
tight fit; twisted beam; all ok in the end ...
we also had a kickspace heater on the job and had to integrate a design for the grill into our finished cabinets, as well as make the heater accessible from the top for later repairs.
so, a removable floor was installed,
and the drawers in the lower case are in a separate cabinet that slides in and out of the main cabinet.lots of door parts, something like 85 or 90 pieces, plus the panels.we finished and assembled everything in the shop before loading it up for the jobsite.
below you can see the way we accommodated the 46" tv in the 44" cabinet opening with the retractable doors....
and yesterday, we installed the 'turnstyle' hardware that arrived last week from england.
the finished interior of the left cabinet ... it's a wrap ....
with the big windows to the right, this was a hard project to photograph so i have included these two other images. the sunlight sort of emphasizes the 'orange' in the finish that is much more subdued in person. a challenging project, all in all .. below are a couple pictures of the original cabinets that inspired them, and here is a link to my website listing on them ...

More News From The Metal Shop

After a short break for some odds and ends .. fireplace screens, a couple of repairs, a very short one step railng, and some work on a couple more cockatoo chairs, Sam has headed into another big railing project with his builder friend Scott Thompson. This design is one loosely based on a previous project for a contemporary house Scott built in 2008.
These are the first two completed sections and Sam and Jim oiled them up before they left today. I haven't been to the house or seen the full drawing, but these two 7' sections will be installed next week and measurements will then be taken for the other 7' section that will connect them and complete the open balcony area. Then I understand there are at least two angled railings that go down the stairs ... I can't wait to see the finished house ....
Here's an end view showing the half posts that will bolt to the inset beams at the ends of the open section. The railings jut out from the posts on short angles so they can attach to the vertical edges of the beam which will provide a secure and rigid connection. Apparently there are some other angled elements on the floor below that suggested this interesting and artistic concept. I'll have to see it when it's all finished.
As usual, Sam made the drawings and then Trevor cut a spacing jig on the cnc that enables Sam to quickly and accurately weld up the pieces.....
The angled jigs were a little trickier, but a lot smaller and worked slick ...

Sam's Balcony

A couple of weeks ago, Sam installed the balcony he was working on back in September and October ... It was a very cool project with some somewhat daunting challenges. Build it here ... install it there, 15' in the air ... Make it safe ... That kind of stuff. I swung by last week and took some pictures ... Looks like it was made to be there .. Click the photos to enlarge them ..
The platform with it's expanded steel floor and outline of the rails
Sam had made a couple of sketches but mainly, on this one, worked as the spirit and his vision moved him ..
Until he had had basic decorative design figured out ...
Next were the support brackets with some ideas sketched in ...
Back to the circular elements of the main railingand then a test assembly on the wall of the shop ...
All welded up and ready to prime and paint
One of the fishies on the 'floor' of the balcony ...
From afar
From below
From the end, showing the 4 supporting brackets

Sam's Railing is Installed !

Sam finished up his railing Wednesday .... He and Jim spent an hour and a half on site bolting the posts to the shoes ... It took longer to drive there than to install the whole thing ... Good measureing and careful planning get the job done ....

Approaching the terrace .. Click the pictures to enlarge them

Now you know why they needed a railing

This has been kind of a big railing project. It's out of town, (New Hampshire), it's a long one. (40' or so) and it's complicated. The builders placed tubes in the ground where they wanted the posts and backfilled around them, planning to pour the posts in place also, I believe. It turned out to be more complicated than that. Sam worked through it, and even though it made for some extra work on his part, he went the extra mile to get it right. There's a gate on the left end where the steps are ....
To start, we decided to make a portable form and construct the posts with detachable 'shoes'. Each shoe with a piece of 3/4" rebar welded to the bottom of it. The form was designed to hold the posts level straight and square while the concrete was poured and setting up. He had to go back after the concrete set up in the tubes, snap his level top lines and measure from inside of post to inside of post on each section. With the jogs and level changes, it involved a little fancy engineering, but when he makes the two hour tip this week with the finished railing parts, we're both confidant that it will bolt right into place. I have not been to the site, but it's on the Connecticutt River and appears to be a striking spot .... Click the pictures to enlarge them.

Setting up the jig for a test run outside the metal shop in the backyard

The posts with the 'hangers' welded on

The 2" tubing with caps welded on and ground smooth...

Some of the spindles and frame parts

A close up of the connections

Ready to paint