Cherry lumber was milled down to the proper size and planed smooth. It was then run through a molding machine using custom knives we designed. This gave the wood its unique design for the door frames.

 

Each board was measured for length and recorded. Each knot or blemish that needed to be removed was also noted for each board. This information was entered into custom optimization sofware that we wrote. The software told us where to cut each board to produce all the door parts, giving us virtually no waste in the end.

 

The door frame components cut to length were then taped to prevent splitting when cutting the miter angle on their ends. The tape also protected the wood from the glue used when gluing the boards together to produce the final frames.

 

The door frame components after cutting the miters.

 

Each door was dry-fit to ensure proper fit before glue-up.

 

The end of each door frame component had a biscuit slot cut into it. This allowed wood biscuits (small, flat football shaped wood splines) to be used to align and strengthen the glued up frame corners.

 

After the biscuits were inserted and the glue was applied, each door was clamped into custom squaring and flattening jigs.

 

Batches of doors were glued up together. With over 60 doors produced for the whole house, they had to be done in batches due to the room required.

 

The doors were then fitted with center panels and finished using a custom dye formulation and then clearcoated with a vinyl sealer and three coats of lacquer.

 

The copper beads for the inside panels were cut from 1/4" Corian and then given a bullnose edge. Working with strips of Corian this small requires special tooling and alot of patience. The beads were then sprayed with a copper coating.

 

 

The beads were glued in place onto the edge of the door center panels.

 

Finished door with beads. Also visible are the pockets cut into the doors by the CNC machine to accept the copper grape clusters.

 

A master copy of the grape clusters was cut on the CNC machine. A set of silicone rubber molds was made from this master copy.

 

liquid urethane resin was mixed and poured into the molds.

 

The resulting piece is a urethane resin copy of the original.

 

The resin castings were hand cleaned to remove flashing and imperfections to prepare for the surface coating.

 

The grape clusters were sprayed with a special metallic coating which is pure ultra-fine copper powder suspended in an acrylic binder. When cured, this leaves a pure copper coating on the surface. Since it is realy copper, the parts had to have a lacquer clearcoat applied to prevent eh copper from oxidizing and turning green over time.

 

The grape clusters wre glued into the pockets on th doors. Due to the accuracy of the CNC machine and allowing for the shrikage of the molds and castings, the fit is extremely tight with only several thousandths of an inch to spare.