The base cabinets were installed first, then the granite countertop and back wall were installed.

 

The structural cabinet components for the top of the unit were installed and the ventilation and electrical work was done. This unit housed many switches and three separate electrical circuits. These circuits feed two wall outlets on the inside of the side walls of the unit, the overhead lights, vent fan, cooktop igniters and light switches to control all of the kitchen's overhead lighting.

 

Copper sheets were glued to 1/4" plywood backer boards and then the assembies were bent and glued to the arch.

 

The glued panels were weighted down and clamped to the arch.

 

The copper panels were meticulously buffed to a mirror finish.

 

After buffing, the copper panels were sprayed with a lacquer clearcoat to prevent oxidation and keep the copper shiny permanently.

 

The finished arch unit, ready for installation.

 

The arched mantel was carved on the CNC machine and then the carvings were cleaned and sanded by hand.

 

The components for the light boxes were cut on the CNC machine.

 

The rough face of the top unit was glued up into a complete assembly.

 

The components for the arched light boxes were assembled.

 

The finished cherry skins were installed on the rough upper unit and the arch was installed along with the large restaurant grade vent system.

 

The finished carved mantel was installed on the unit. Here, the pocket for the coat of arms can be seen after it was cut into the finished mantel. The mantel was carved from a single piece of cherry measuging 12 inches wide by 3 inches thick by 8 feet long.

 

One of the three lithophane carvings is shown here, installed with the custom gloss black and beaded cherry frame.

 

The first light test of the three lithophane carvings.

 

Finishing touches were added such as the custom carved columns and the gloss black arch joining the copper to the cherry components.

 

The coat of arms was carved into machineable wax on the CNC machine. This wax master was then used to make a mold so that the final coat of arms could be cold-cast using copper powder and urethane resin.

 

The finished column for the base of the wall unit was split in half for installation left and right of the cooktop.

 

The first column was test fit and a custom Corian pedestal was made for it to sit on. The custom Corian ring at the base of the column is also seen here, prior to polishing.

 

An early color test of the coat of arms. Here, silver and gold leaf were applied. Eventually the colors were rejected.

 

A second color test with red, blue and gold produced a beautiful result. In the end though, it was decided that the colors were too bright for the overall design and the final coat of arms was coated with pure copper and an acrylic clear coat was applied.