http://www.greengatewoodworks.com/black-walnut-crib daily 0.75 2018-01-29 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613630477-UIE4B7ZQXACXADRTM8NU/IMG_2325.JPG Daughter's Black Walnut Crib When my daughter came along I decided to make a crib for her, so I went and picked up some walnut from the mill and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613630477-UIE4B7ZQXACXADRTM8NU/IMG_2325.JPG Daughter's Black Walnut Crib When my daughter came along I decided to make a crib for her, so I went and picked up some walnut from the mill and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613628266-ZL431337SG3495GT9RO6/Gillian%27s+Crib+12-8-13_IMG_9774.JPG Daughter's Black Walnut Crib The finished crib in her nursery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613627778-8C1OQHFI4YH0ZDPIEW1U/Gillian%27s+Crib+12-8-13_IMG_9776+cropped.jpeg Daughter's Black Walnut Crib Another shot of the finished crib https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613641638-OLAGYD88K0HJZL0NHMNT/IMG_3510.JPG Daughter's Black Walnut Crib The satisfied client http://www.greengatewoodworks.com/new-blog daily 0.75 2019-12-25 http://www.greengatewoodworks.com/new-blog/2019/12/25/amy-l monthly 0.5 2019-12-25 http://www.greengatewoodworks.com/new-blog/2019/12/9/robin-k monthly 0.5 2019-12-09 http://www.greengatewoodworks.com/new-blog/2019/8/26/chris-m monthly 0.5 2019-08-26 http://www.greengatewoodworks.com/new-blog/2019/2/10/gina-d monthly 0.5 2019-02-10 http://www.greengatewoodworks.com/new-blog/2019/2/10/eric-t monthly 0.5 2019-02-10 http://www.greengatewoodworks.com/new-blog/2017/7/31/jason-e-1 monthly 0.5 2019-02-10 http://www.greengatewoodworks.com/new-blog/2016/10/27/chris-g monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2017/7/31/christine-d monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2016/10/27/suzi-q monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2016/10/27/michael-g monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2016/10/27/jeff-h monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2016/10/27/sara-s monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2016/10/27/cwafjrst0gr018oklod7orda6o8gfn monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2016/10/27/jenn-s monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2016/10/27/r95v3eb75mygio8h2u9s5quiitf30w monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2016/10/27/dana-m monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2017/7/31/kathleen-m monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/new-blog/2016/10/27/ali-c monthly 0.5 2017-08-20 http://www.greengatewoodworks.com/reclaimed-table daily 0.75 2018-01-29 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606972936-RHMF8BMWZROPZM8R66IC/IMG_4835.JPG Reclaimed Farmhouse Table I was commissioned by an existing client to create a dining table for her daughter. They wanted to use reclaimed materials, so I looked around and came across these joists that were pulled out of a 1920's home and were set to be thrown away. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606972936-RHMF8BMWZROPZM8R66IC/IMG_4835.JPG Reclaimed Farmhouse Table I was commissioned by an existing client to create a dining table for her daughter. They wanted to use reclaimed materials, so I looked around and came across these joists that were pulled out of a 1920's home and were set to be thrown away. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606961670-TOIM89JIZG3L2G8NVM42/IMG_0446.jpg Reclaimed Farmhouse Table After removing many, many nails and cleaning up the original boards, I turned them into this farmhouse table. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606960239-72MLA0SEHZ9CP4U5CU03/IMG_0424.jpg Reclaimed Farmhouse Table Measuring approximately 38" across and 78" long, the table seats 6 comfortably. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606962796-4TS36JB5QVV1T8HDGNCZ/IMG_0470.jpg Reclaimed Farmhouse Table The breadboard ends on the table help to keep the tabletop flat while still allowing it to expand and contract with seasonal changes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606958223-Z9J7YFC1NJJMV1U25BZY/IMG_0385.jpg Reclaimed Farmhouse Table I fabricated and installed these black walnut butterfly keys, also known as Dutchmen, to secure a crack in one of the boards and keep it from growing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606963609-Z8V0BHB48RYFLQ2YJOHC/IMG_0474.jpg Reclaimed Farmhouse Table A slight taper to the legs gives them a little visual interest and reduces the visual weight of the legs so they don't overwhelm the overall design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606961077-LTDI32D6OG61C84UESTB/IMG_0447-crop2.jpg Reclaimed Farmhouse Table I chamfered the corners of the legs for an additional detail. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606962925-RH8QQRWGHFI5EB25GS6Q/IMG_0448.jpg Reclaimed Farmhouse Table Finished shot of the completed table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477607038652-Z3DQDG2AIB5ZWHCCD4Z7/Victoria+murray+and+her+table%2C+delivered.jpeg Reclaimed Farmhouse Table My clients (the recipient's parents) delivered the table to their daughter in Massachusetts and sent me this picture of her and her fiancé with the table in its new home. http://www.greengatewoodworks.com/treadle-base-side-table daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614851379-556KWRPZH38K338A5VDO/IMG_4800.JPG Treadle Base Side Table A client asked me to make a table top for an antique treadle base. She wanted to use reclaimed lumber, so we took a trip to the architectural salvage yard and found a bundle of old tongue-and-groove flooring. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614851379-556KWRPZH38K338A5VDO/IMG_4800.JPG Treadle Base Side Table A client asked me to make a table top for an antique treadle base. She wanted to use reclaimed lumber, so we took a trip to the architectural salvage yard and found a bundle of old tongue-and-groove flooring. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614859048-R52T66YMUBF2MBVXIB29/IMG_4852.JPG Treadle Base Side Table Shot of the finished table. After milling the wood it had lost some of it's darker character, so I used a blowtorch to bring it back and then sealed it with several coats of lacquer. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614858164-GKD0X9LPSZVQ103E23BQ/IMG_4857.JPG Treadle Base Side Table A shot showing some of the details of the treadle base https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614862928-T3D2G6M0IA3C7M0FLA9F/IMG_4858.JPG Treadle Base Side Table Side shot of the finished table http://www.greengatewoodworks.com/mahogany-outdoor-table daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477780834843-KXPN5KWAZBZ1JF4QJLQ0/IMG_4710.JPG Mahogany Outdoor Table The client’s original table was falling apart due to rot. I suggested building a new top from Brazilian mahogany because of its ability to withstand the elements. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477780834843-KXPN5KWAZBZ1JF4QJLQ0/IMG_4710.JPG Mahogany Outdoor Table The client’s original table was falling apart due to rot. I suggested building a new top from Brazilian mahogany because of its ability to withstand the elements. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477780837166-0WGRU0PJBPYCQN65MK9A/IMG_4789.JPG Mahogany Outdoor Table The new top assembled and sanded down https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477780839122-9CA83D5BJ5VZJ0TJ5WSM/IMG_4821.JPG Mahogany Outdoor Table The finished table delivered. I reused the legs at the client's request and added a central hole for their umbrella. http://www.greengatewoodworks.com/new-gallery-1 daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477779768312-X5LTOY3ITEWSK70Y69NB/IMG_3867.JPG Rocket Ship Bed I received a call from a client who wanted a rocket ship bed made for her son's birthday. She provided a picture of what she was looking for, so I scaled up some drawings. In this picture is one of the sides of the bed, cut out and shaped. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477779768312-X5LTOY3ITEWSK70Y69NB/IMG_3867.JPG Rocket Ship Bed I received a call from a client who wanted a rocket ship bed made for her son's birthday. She provided a picture of what she was looking for, so I scaled up some drawings. In this picture is one of the sides of the bed, cut out and shaped. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477779772855-8PLIKM47D6ZC94ZVIRR5/IMG_3873.JPG Rocket Ship Bed Side view of the assembled bed with the portholes cut out and installed. The client wanted to paint the bed herself to save on cost, so I delivered the product unfinished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477779771593-AE1GPRC8SMXG1YCTYTL8/rocket+bed+collage.jpeg Rocket Ship Bed The finished product in place and ready to use. The client did a great job painting, and the bright colors really bring it to life. http://www.greengatewoodworks.com/painted-oak-crib daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615764485-7F9R22II8RVBF9MQ1HLW/CIMG0018.jpg Painted Oak Crib https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615764485-7F9R22II8RVBF9MQ1HLW/CIMG0018.jpg Painted Oak Crib https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615765475-1633X4MT3VFRCFOKAKSW/CIMG0049.jpg Painted Oak Crib When I found out my niece was on the way, I wanted to make a crib for her. My brother-in-law and his wife showed me a design they liked, and I replicated it in red oak. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615767553-3BQ9IAY2IYGDX3G6567K/CIMG0058.jpg Painted Oak Crib Here, the curved top rail for the back wall of the crib is clamped up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493239505132-814JB76CWIYMQ86LGADO/IMG_0123.JPG Painted Oak Crib The finished crib delivered to her nursery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493239527693-D8DVUU1I2CBNWNHZWEDA/IMG_0124.JPG Painted Oak Crib Closer shot of the finished crib. Since she grew out of it, it's been used by her two younger siblings. http://www.greengatewoodworks.com/kitchen-nook daily 0.75 2018-02-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782188914-B1W86RI6WUXR5HO3U93W/IMG_1190.jpg Chester Springs Flitch Table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782189286-D3XO1DT22AJQTPEM9OWG/IMG_1197.jpg Chester Springs Flitch Table As part of a larger kitchen nook renovation, I made this custom dining table from a white oak flitch. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782188914-B1W86RI6WUXR5HO3U93W/IMG_1190.jpg Chester Springs Flitch Table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782189379-LLOEEFJ39O2G6D7LQAZT/IMG_1214.jpg Chester Springs Flitch Table Looking down the live edge of the table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782189733-ZH0WRL4JN87TGWOCO6ZP/IMG_1221.jpg Chester Springs Flitch Table The custom base was fabricated by John Parker of The Painted Garden, Inc based on my design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782190151-765ALJ13BGOVVVEYTPHK/IMG_1247.jpg Chester Springs Flitch Table Embedded in the central hole of the table is a tree of life medallion the client purchased. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782188745-48N36GUR7QGVTKYM4UTD/IMG_1188.jpg Chester Springs Flitch Table A wider shot of the finished table and the completed kitchen nook. http://www.greengatewoodworks.com/arts-crafts-end-table daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613425321-1W2FQFFOIRJZEI90KJR8/Jeff+Lohr+2nd+level+class+product+oiled+2.JPG Lohr Class Arts & Crafts End Table An Arts and Crafts style table I did as part of a furniture making course I took. The course was run by Jeff Lohr (http://www.jdlohrwood.com/), and I highly recommend it if you have an interest in that sort of thing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613425322-LKEGCW4MHCIYX9ZK54YE/Jeff+Lohr+2nd+level+class+product+2.JPG Lohr Class Arts & Crafts End Table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613425321-1W2FQFFOIRJZEI90KJR8/Jeff+Lohr+2nd+level+class+product+oiled+2.JPG Lohr Class Arts & Crafts End Table An Arts and Crafts style table I did as part of a furniture making course I took. The course was run by Jeff Lohr (http://www.jdlohrwood.com/), and I highly recommend it if you have an interest in that sort of thing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613427400-7HKHELUM79DBDMSFNUXR/Jeff+Lohr+2nd+level+class+product+oiled.JPG Lohr Class Arts & Crafts End Table http://www.greengatewoodworks.com/barnwood-buffet daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605450203-VQAOE7FK2VOFNUY37NCW/IMG_8124.JPG Barnwood Buffet I was commissioned to make a buffet from some old barn beams I had obtained. I ended up using four of these pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605450203-VQAOE7FK2VOFNUY37NCW/IMG_8124.JPG Barnwood Buffet I was commissioned to make a buffet from some old barn beams I had obtained. I ended up using four of these pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605411600-VHP0VO0SRIIHCIA20H5W/Buffet-Barnwood+5-13-16+IMG_1646.jpg Barnwood Buffet Finished shot of the buffet https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605438358-27F9PNJ5NYML7CDQH3GL/Buffet-Barnwood+5-13-16+IMG_1653.jpg Barnwood Buffet Side view https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605433863-V6DUI0752P6RZXY2WSFY/Buffet-Barnwood+5-13-16+IMG_1659.jpg Barnwood Buffet Close up of the breadboard ends https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605443876-WAI900ZA261Q4U65M1DX/Buffet-Barnwood+5-13-16+IMG_1663.jpg Barnwood Buffet Looking down the dovetailed drawers. I had orignally picked out different drawer pulls, but when they arrived they didn't have the feel I wanted. I opted for larger, heavier pulls that worked better for this piece. Little details can make a big impact on a project like this. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605420421-TOTX9V63CS6A5Y0DC486/Buffet-Barnwood+5-13-16+IMG_1638-36-flat.jpg Barnwood Buffet Shot of the finished buffet before being delivered to the client's home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605531972-T9XGCZPBGTAQT9U0Z3PX/IMG_9524.JPG Barnwood Buffet Picture of the photo shoot with Flip Krugler. Pogo the Supervisor Cat keeps an eye on things. http://www.greengatewoodworks.com/adirondak-chairs daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615000809-8IJXDQBGHK2DB3FPNMYN/best_chairs+in+yard_profile_turk+daisy.jpg Adirondak Chairs My dogs hanging around a set of adirondack chairs I made. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615000809-8IJXDQBGHK2DB3FPNMYN/best_chairs+in+yard_profile_turk+daisy.jpg Adirondak Chairs My dogs hanging around a set of adirondack chairs I made. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615000881-R0GFFSPEXK7H475BX9TL/best_chairs+in+yard3.jpg Adirondak Chairs Looking out over my back field https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615007984-DB4Y54ZNOJKVZ63NZNP0/little+chair+unpainted.JPG Adirondak Chairs I made a half scale version of the chairs as a gift for some friends. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496864921881-5AYKELZHHTPUUHROD8US/baby+andy+in+little+chair.JPG Adirondak Chairs The half scale chair and its future occupant. http://www.greengatewoodworks.com/new-gallery daily 0.75 2016-10-27 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477591952910-YXCIDKKW0EFF094TPNR3/IMG_0446.jpg Our Work - Handcafted Furniture https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477591952910-YXCIDKKW0EFF094TPNR3/IMG_0446.jpg Our Work - Handcafted Furniture https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477592313175-JF7SA133NVKIGUT2LYNO/IMG_9244-R.jpg Our Work - Defining Built-Ins https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477592328810-VIXS77G2BU7HEQJSXMUF/Zug+mantle+%281%29.jpg Our Work - Custom Woodworking Unique elements made to blend seamlessly with your home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477592417631-3GFM2KQCIZ7DAH46ZNT2/Sketch-2.jpg Our Work - Custom Home Solutions http://www.greengatewoodworks.com/kids-art-desks daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614355118-D8U6X4KFKMP6UJ96I7XN/IMG_6371.JPG Kids' Art Desks https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614355118-D8U6X4KFKMP6UJ96I7XN/IMG_6371.JPG Kids' Art Desks https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614497152-V1FYBQPY0Y4ZLIRRFJ2Y/IMG_7855.JPG Kids' Art Desks I made a pair of these kid's art desks as gifts for my cousins' kids based on a design I saw online. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614497946-O3XHE2FOA7C132XK3TRN/IMG_7856.JPG Kids' Art Desks The top lifts up and are secured at various angles with a brace attached to the underside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614510905-W06YOK0C5R73AC7NRBZR/IMG_7870.JPG Kids' Art Desks Each desk has a small drawer for storage. The white T-shaped dowels set in the desktop slot keep papers and pens from sliding off the desk while it's raised. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614503859-U0E5B8VG6GMIEI7EHCQZ/IMG_7863.JPG Kids' Art Desks Both desks can be raised up as the kids grow to provide years of usefulness. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614507000-IMI429503QGLKMZXRER9/IMG_7867.JPG Kids' Art Desks Another shot of the completed desk http://www.greengatewoodworks.com/leprechaun-door daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496880512429-XS2MGVH10JDQERK0OXWZ/119.JPG Leprechaun Door I found a request from a person in an online woodworking forum looking for a "leprechaun door" to install as a creative patch to a hole in their wall. Seemed like an interesting project, so after we worked out a deal for it, I got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496880512429-XS2MGVH10JDQERK0OXWZ/119.JPG Leprechaun Door I found a request from a person in an online woodworking forum looking for a "leprechaun door" to install as a creative patch to a hole in their wall. Seemed like an interesting project, so after we worked out a deal for it, I got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477659891229-GOMHXDUVAHAHY5OPT8J8/20140224_192203_resized.jpg Leprechaun Door https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496880529019-SZAFDNQ8T2F1UFQ2QUOB/IMG_3881.JPG Leprechaun Door Front shot of the leprechaun door. I built it out of some scrap poplar and plywood I had laying around the shop. Overall it's about 6" wide by 11" tall by 3" deep to fit inside their wall cavity. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477659944692-HRUY6V2EP287CCVADEH0/IMG_3884.JPG Leprechaun Door I shipped the door out unfinished so the client could paint it and add their own hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496880523208-ENKCDS4N4AXKQIRMK5JV/132.JPG Leprechaun Door I received this photo back from the client of the finished and installed door. It was a fun little project - took about three hours to complete - and I got a nice original painting in return for my daughter's room. http://www.greengatewoodworks.com/cherry-mantle daily 0.75 2017-06-07 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477783036594-2W4W8RFYAA3EY2833NI6/Cohn+bathroom+renovation+-+cabinet+construction+5.JPG Cherry Vanity As part of a larger bathroom renovation, I was commissioned to make a custom cherry vanity. Here the base cabinets have been assembled and had the face frames attached. All the cherry face frame and drawer parts were milled down from rough lumber in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477783036594-2W4W8RFYAA3EY2833NI6/Cohn+bathroom+renovation+-+cabinet+construction+5.JPG Cherry Vanity As part of a larger bathroom renovation, I was commissioned to make a custom cherry vanity. Here the base cabinets have been assembled and had the face frames attached. All the cherry face frame and drawer parts were milled down from rough lumber in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477783036886-XVPN1H53YG28CNIBEYQB/Cohn+bathroom+renovation+-+cabinet+construction+6.JPG Cherry Vanity The end panel on each drawer base is a cherry veneer, left unstained to provide contrast to the rest of the piece. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477783038845-CHS0RJNZQQ52ZNZV1FIN/Cohn+bathroom+renovation+-+cabinet+construction+19.JPG Cherry Vanity Installed in the client's home. The cabinet doors were built with the same cherry veneer to match the end panels. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477783039232-6E7HDB34SJOR2F7MYMXI/Cohn+bathroom+renovation+-+finished+cabinet+6.JPG Cherry Vanity Hardware installed, along with the top and sink. The piece was finished with several coats of polyurethane which helped to mellow the contrast between the stained face frame and the unstained veneer panels. http://www.greengatewoodworks.com/painted-oak-granite-table daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477781829653-THSJNML6G4KJVR2DL4LO/Monica+and+Gary+Cummins+table+project+-+finished+table+2.JPG Chester Springs Painted Oak & Granite Table A small kitchen table I made for my neighbors. They had an extra slab of granite left over from their kitchen renovation and wanted to turn it into a table that would match their existing dining room table. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477781829653-THSJNML6G4KJVR2DL4LO/Monica+and+Gary+Cummins+table+project+-+finished+table+2.JPG Chester Springs Painted Oak & Granite Table A small kitchen table I made for my neighbors. They had an extra slab of granite left over from their kitchen renovation and wanted to turn it into a table that would match their existing dining room table. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477781831823-TKBQAXMI5T2405OG6WX7/Monica+and+Gary+Cummins+table+project+-+finished+table.JPG Chester Springs Painted Oak & Granite Table Another shot of the table with slightly better lighting http://www.greengatewoodworks.com/distressed-flooring daily 0.75 2026-02-13 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837833618-1EOLU07PS7RS1MNM1V2L/IMG_8198.JPG 1217 Distressed Flooring While my own house was under construction I lived with a mish-mash of old oak floors, plywood patches, and ancient linoleum for a few years before I was ready to install new floors. Here you can see the old oak flooring piled up after demolition. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837833618-1EOLU07PS7RS1MNM1V2L/IMG_8198.JPG 1217 Distressed Flooring While my own house was under construction I lived with a mish-mash of old oak floors, plywood patches, and ancient linoleum for a few years before I was ready to install new floors. Here you can see the old oak flooring piled up after demolition. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837835390-S4375CBXA610EZ1YPCU0/IMG_8235.JPG 1217 Distressed Flooring After the old floors had been removed, new 8" wide red pine floors were installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837836413-TPE0JGNOP8YT2FTS4CQ6/IMG_8245.JPG 1217 Distressed Flooring New floors in the dining room and office. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837836874-5PI3OH4W0S0US03TMHKG/IMG_8264.JPG 1217 Distressed Flooring New floors being installed in the kitchen and living room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837838324-LKAN2EPIBKCQ647AMCPV/IMG_8282.JPG 1217 Distressed Flooring To get the antique look we wanted, I hammered in masonry cut nails through the face of the planks. It ended up being 2,420 nails (63 lbs worth). It'll be a few years until I forget how bad it was and agree to put new floors in upstairs. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837842173-2NQVEWG5S3QRJXUNTMXZ/IMG_8318.JPG 1217 Distressed Flooring After sanding I applied a preconditioner. This helps even out the color of the stain when it goes down. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837843794-BH79BH881P2ROLW1ED8M/IMG_8404.JPG 1217 Distressed Flooring After staining and a few coats of polyurethane, the floors were finished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770942291319-DX66GQ4GA99AVHFHGWMW/IMG_8814.JPG 1217 Distressed Flooring Instead of trashing all the original flooring from our house, I took some of it and turned it into these picture frames. http://www.greengatewoodworks.com/frames daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975259834-4JVFHRJMB1907TGY6V19/IMG_8814.JPG Reclaimed Flooring Picture Frames Picture frames I made from reclaimed flooring. I made four standard sizes: 3x5, 4x6, 8x11, and 11x14. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975259834-4JVFHRJMB1907TGY6V19/IMG_8814.JPG Reclaimed Flooring Picture Frames Picture frames I made from reclaimed flooring. I made four standard sizes: 3x5, 4x6, 8x11, and 11x14. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975253451-HZMHNTWBIW6GAZZ4B1B0/4x6+back+bright.jpg Reclaimed Flooring Picture Frames Hardware on the back of each frame allows for hanging it in either direction. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975253581-PAN9W0PU0AB2NE8MSEQ0/4x6+detail+bright.jpg Reclaimed Flooring Picture Frames The original cut nails in the floor were left for visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975257070-FAN1VBXA3KAXFZCP56XB/IMG_1749.JPG Reclaimed Flooring Picture Frames Close up shot of the mitered corner and another flooring nail https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496883125911-SC4AMP9O6GRWI817FIBU/Gillian+picture+in+reclaimed+frame.jpg Reclaimed Flooring Picture Frames I kept one frame for myself to hang some artwork my daughter made in nursery school. http://www.greengatewoodworks.com/new-gallery-3 daily 0.75 2017-08-16 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083931035-BA1PQWXM6L7ZU2TM4R4P/IMG_9228.jpg Berwyn Built-Ins For this set of cabinets, the client wanted plenty of storage along the bottom with a series of open shelves and cubbies on top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083931035-BA1PQWXM6L7ZU2TM4R4P/IMG_9228.jpg Berwyn Built-Ins For this set of cabinets, the client wanted plenty of storage along the bottom with a series of open shelves and cubbies on top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083928545-B3XAFUEM05A1GD20WMPJ/IMG_9232.jpg Berwyn Built-Ins They also wanted an area to house their TV and other electronics. I designed that area to extend forward beyond the adjacent cabinets to provide visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083955217-ZGT6XYFPTNUHUX6C9L37/IMG_9251.jpg Berwyn Built-Ins Closer shot showing some of the door and trim details https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083936183-8TIFO53ZW9D1571WH2IR/IMG_9237.jpg Berwyn Built-Ins Bump out detail on the countertop https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083939699-B2GAUOJ6FFIW8DB59OZ2/IMG_9241.jpg Berwyn Built-Ins In the first round of design this was intended to be a desk area, but it was later changed to cabinets. Now it seems to have become a bar, which is always a good move. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083948282-CLS4JDCV78ZWEU63WJZM/IMG_9247-R.jpg Berwyn Built-Ins The client wanted the built-ins to frame the doorway, which you can see with this view into their dining room. The whole piece was tied together with a small crown detail and baseboards to match their existing trim. http://www.greengatewoodworks.com/hot-tub-to-garden daily 0.75 2018-02-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975389781-N9YWRO18UUGHEAB82NU0/IMG_7555.JPG Philadelphia Hot Tub to Garden The clients I had built this ipe deck for a few years back, called up and told me their hot tub had finally died. They decided that instead of getting a new one, they wanted the space converted into a raised planter bed. Here is the hot tub shortly after I began cutting it up to remove it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975389781-N9YWRO18UUGHEAB82NU0/IMG_7555.JPG Philadelphia Hot Tub to Garden The clients I had built this ipe deck for a few years back, called up and told me their hot tub had finally died. They decided that instead of getting a new one, they wanted the space converted into a raised planter bed. Here is the hot tub shortly after I began cutting it up to remove it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493239992982-K98JSWT7K3P3D2P1PKYR/IMG_6940.jpg Philadelphia Hot Tub to Garden https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975392753-BA9XTE5W6P8TBTO4YIFF/IMG_7630.JPG Philadelphia Hot Tub to Garden After removing the old hot tub and putting in some drainage lines, I framed up a new floor and side walls. I put down PVC sheets to line the bottom and then drilled holes through it to allow for water to flow through to the drainage lines. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975396991-HYPOT4RBO2LNQ0XMY357/IMG_7654.JPG Philadelphia Hot Tub to Garden After lining the interior with filter fabric, I applied ipe deck boards to the exterior and interior walls so that they would line up exactly with the existing decking. Over time, they will weather to the same silver color as the rest of the decking. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975399152-8L5G8CRG1L0U55AN0IOR/IMG_7656.JPG Philadelphia Hot Tub to Garden The last step for me was adding ipe deck boards across the top of the walls. After that, the landscapers brought in topsoil. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975400477-F206PYUOHV9RIE8FANFY/IMG_9973.JPG Philadelphia Hot Tub to Garden A few months later I was back on a rainy day and got this finished shot of the vegetable garden going strong. http://www.greengatewoodworks.com/new-gallery-2 daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838114358-Z81AEZ28PL3MHRU7R43E/IMG_6397.JPG Barn Beam Mantle Clients of mine requested a barn beam mantle for their new home, so we took a trip to the sawmill and picked out on they liked. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838114358-Z81AEZ28PL3MHRU7R43E/IMG_6397.JPG Barn Beam Mantle Clients of mine requested a barn beam mantle for their new home, so we took a trip to the sawmill and picked out on they liked. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838116354-AY6PJB9DG88XD5UADNY1/IMG_6399.JPG Barn Beam Mantle I cleaned up the back side of the beam with my router sled for ease of installation. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838113916-XT7OWF0YIT666D28NCYZ/IMG_2501.JPG Barn Beam Mantle The installed mantle. I used a thin epoxy to secure some weakened areas on the beam and finished it with lacquer. They both soaked into the wood giving it a deep, rich color without using any stain. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838111710-A4QZZ0RVAZRLUWTMK4OA/IMG_2480.JPG Barn Beam Mantle Looking down the face of the mantle https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838111973-6D3ZYF9I88NB0NW0XFSG/IMG_2478.JPG Barn Beam Mantle The marks where the beam was originally hewn by hand are still visible. http://www.greengatewoodworks.com/toy-truck daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973403774-ZI3T1W8UH8BXUEYMKQMS/Will+Krugler+truck+project+-+before+2.JPG Toy Truck When my nephew came along I had already made a crib for his sister, so I decided to make a toy truck for him. I found this design in a book on toy building. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973403774-ZI3T1W8UH8BXUEYMKQMS/Will+Krugler+truck+project+-+before+2.JPG Toy Truck When my nephew came along I had already made a crib for his sister, so I decided to make a toy truck for him. I found this design in a book on toy building. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973404985-WJGXMQ9JW3BTHTZ9S56L/Will+Krugler+truck+project+-+before.JPG Toy Truck https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973411768-Y39PNDN42Y7H5HFN688K/Will+Krugler+truck+project+-+cab.JPG Toy Truck The cab of the truck shaped out of alder https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973401417-88GOKTK4UBIL8PD6JR68/Will+Krugler+truck+project+-+bed+and+cab+on+chassis+3.JPG Toy Truck I used some ipe scraps from another job to make the wheel wells. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973400008-LASGPUO3VLPH91ZV434G/Will+Krugler+truck+project+-+axle+frames+on+chassis.JPG Toy Truck With some more alder and a few small dowels, the details began to take shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973422137-5Z4JSSKVC52TPWAU0MQW/Will+Krugler+truck+project+-+finished+5.JPG Toy Truck The completed truck, finished with several coats of boiled linseed oil. The wheels, like the wheel wells, are made of ipe. http://www.greengatewoodworks.com/new-gallery-4 daily 0.75 2017-08-16 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084679860-F5DJ1E35GH95SCZVLNJ5/Haverford+9-2015++IMG_1044.JPG Haverford Built-Ins A long time client had moved and wanted some built-ins to provide additional storage in their new home. This unit is one of a matching pair in their living room, with the other one being on the far side of the room. Two other units are in a front room of the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084679860-F5DJ1E35GH95SCZVLNJ5/Haverford+9-2015++IMG_1044.JPG Haverford Built-Ins A long time client had moved and wanted some built-ins to provide additional storage in their new home. This unit is one of a matching pair in their living room, with the other one being on the far side of the room. Two other units are in a front room of the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084674316-L6E4SRKQN09GYH2D3W1O/Haverford+9-2015++IMG_1045.jpg Haverford Built-Ins Close up shot of the living room lower cabinets. Both pairs of built-ins in this room have inset flat panel doors and oil rubbed bronze hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084679312-KZZIU5MORCAW4U4YESWK/Haverford+9-2015++IMG_1049.JPG Haverford Built-Ins Finished living room units, right side. Two fixed shelves were included on each of these back room units to accomodate the weight of the client's vinyl record collection. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084686279-HHUS5658OWVAJBJJKN32/Haverford+9-2015++IMG_1056.JPG Haverford Built-Ins This pair of cabinets sits in the front room of the house. They also feature inset flat panel doors and oil rubbed bronze hardware. Each unit flanking the fireplace has an existing recessed overhead light incorporated into it. The client installed a wirelessly controlled LED bulb in each one that allows the color of the light to be adjusted via a smartphone. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084681454-03I2O04NY1G3VRNQWJ7M/Haverford+9-2015++IMG_1056-btm.jpg Haverford Built-Ins The front room units incorporated high baseboards to tie them into the existing trim scheme. http://www.greengatewoodworks.com/garden-sign daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974883950-LD6QU0OYY6LUJ0E6PS9F/IMG_2488.JPG Father's Day Garden Sign A friend commissioned me to make a sign for his father. Since it was going to be used outdoors, I made it out of ipe, a brazilian mahogany that will stand up to the elements. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974883950-LD6QU0OYY6LUJ0E6PS9F/IMG_2488.JPG Father's Day Garden Sign A friend commissioned me to make a sign for his father. Since it was going to be used outdoors, I made it out of ipe, a brazilian mahogany that will stand up to the elements. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974883333-8ZWCJN66FGJA9WY2J6ZV/IMG_2489.JPG Father's Day Garden Sign After deciding upon a font, I printed out this full scale version and used it to transfer the design to the board. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974886475-XNODDFQP3KRC2SRLU3DM/IMG_2493.JPG Father's Day Garden Sign After transferring the marks with a knife, I traced them with a sharpie for better visibility and began to remove material using a trim router. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974888274-FFO8K7R2BUHJNLEIY14Z/IMG_2495.JPG Father's Day Garden Sign Removing the material is a slow process, but not one you can rush. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974891132-MRQDH3QP24DO6AOWX6FU/IMG_2503.JPG Father's Day Garden Sign After removing all the material and cleaning it up a bit with a chisel and some sandpaper, it was ready to deliver. http://www.greengatewoodworks.com/zug-mantle daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496881628571-3LMUCV2Y1ES00VVJ1O8L/IMG_2592.JPG Media Mantle A long-time client of mine hired me to do a number of different jobs while they were out of town. One of the projects they gave me was to renovate their fireplace and give it more of a rustic feel. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496881628571-3LMUCV2Y1ES00VVJ1O8L/IMG_2592.JPG Media Mantle A long-time client of mine hired me to do a number of different jobs while they were out of town. One of the projects they gave me was to renovate their fireplace and give it more of a rustic feel. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276105-DUFDGFVVF9FQWTAJ7EJV/IMG_0011-B.jpg Media Mantle A shot of the completed project. We installed new cables and a mount for the TV, new fireplace doors, veneer stone to match the exterior of the home, and a custom made cherry mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276079-TPY5TWXXZIGBVJ2ZDIU7/IMG_0011-A.jpg Media Mantle https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276471-979MUPQGEDJAYRCD62H5/IMG_0083.jpg Media Mantle Closer shot of the mantle and TV https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276468-UZFZ3A3UUTXHO42DDMCO/IMG_0087.jpg Media Mantle A closer shot of the mantle https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276853-IQ591NBA5NQTMX10NQCR/IMG_0092.jpg Media Mantle The mantle and corbels were fabricated from a single cherry slab. The original slab had a split in it which I included in the mantle by filling it with a structural epoxy that dries clear. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276851-HBOYE7XEHE0CFCIX5XY2/IMG_0096.jpg Media Mantle Beautiful grain patterns on the custom made corbels http://www.greengatewoodworks.com/gg-sign daily 0.75 2016-11-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974765844-QCU7PZNXJ7G20VZH6PGX/IMG_7944.JPG GG Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974765844-QCU7PZNXJ7G20VZH6PGX/IMG_7944.JPG GG Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974766474-PD0JNEXQRNGEWHAFVX19/IMG_7946.JPG GG Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974767795-9BSS27OSSQZ7B815NIRA/IMG_7947.JPG GG Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974768557-8BPXWYS4TDV49W9WPFY9/IMG_7952.JPG GG Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974770414-WV0TG2V84PA0RK6APDS2/IMG_7962.JPG GG Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974771141-FSAUBQIFF2Q5UL91KWIW/IMG_7963.JPG GG Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974774249-YXXOYKC27C80EXBZK86N/IMG_7976.JPG GG Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974774960-BYKENYKLU6YEX4LT9H1K/IMG_7977.JPG GG Sign http://www.greengatewoodworks.com/mudroom daily 0.75 2018-02-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084214276-594EPT7K8HPZ0UVSA72N/IMG_1250.jpg Chester Springs Nook Bench Part of a larger kitchen nook project, I created this built-in bench and finished it with white chalk paint and antiqued it with a mix of dark and clear wax. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084214276-594EPT7K8HPZ0UVSA72N/IMG_1250.jpg Chester Springs Nook Bench Part of a larger kitchen nook project, I created this built-in bench and finished it with white chalk paint and antiqued it with a mix of dark and clear wax. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084214317-TY5U9KBIOG851P1EPD56/IMG_1253.jpg Chester Springs Nook Bench The bench top lifts up to reveal additional storage space inside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084213588-ND53DU00XTO8A2K7BHNK/IMG_1197.jpg Chester Springs Nook Bench The client had custom cushions made for the bench tops, shown here alongside the live edge white oak table I made as part of the overall project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084212583-CFDANE06G1EP1OH9M9T7/IMG_1141-42-crop.jpg Chester Springs Nook Bench https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493514737929-WRQQV6EEWXQCNILBUXX4/IMG_5971.JPG Chester Springs Nook Bench http://www.greengatewoodworks.com/new-gallery-9 daily 0.75 2017-08-15 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087525313-PUWDFADH8DDHDO0KTQ8Y/murray+before+panorama+big.jpg Philadelphia Ipe Deck This was a deck project I completed back in late 2009 - early 2010. This is a before shot of the original deck. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087525313-PUWDFADH8DDHDO0KTQ8Y/murray+before+panorama+big.jpg Philadelphia Ipe Deck This was a deck project I completed back in late 2009 - early 2010. This is a before shot of the original deck. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087375949-AZSO7QAQG71IATVEP492/IMG_4877.JPG Philadelphia Ipe Deck We installed new footings and a pad to elevate the original hot tub up into the new deck. Then we began to install the framing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087394726-HJFSIYSMNGGI3L3CT2SW/IMG_4982.JPG Philadelphia Ipe Deck Installing the large main beams for the pergola https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087400562-SOT3OG2N0JET9PDHXBS6/IMG_5148.JPG Philadelphia Ipe Deck All the trim work on the deck was made of ipe, as shown here on the post wrap details. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087387771-TEDXOWU9CQP68OG2UKZ1/IMG_4938.JPG Philadelphia Ipe Deck Framing for the main deck stairs https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087416343-YDKD9SEPKLHAM65SEIY0/IMG_5319.JPG Philadelphia Ipe Deck Main deck stairs with ipe decking installed https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087479446-0QGV0569TVM2FO0YV3SY/IMG_6953.jpg Philadelphia Ipe Deck Wide shot of the completed project https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087451276-98WKNHLUQDQODLO2HXGI/IMG_6940.jpg Philadelphia Ipe Deck The hot tub surrounded by the new decking. The tub sits up above the decking approximately 20" so that it's easy to sit on and turn to drop right in. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087470956-7I8533FVQRD2GJVUAWAG/IMG_6943.jpg Philadelphia Ipe Deck Looking down towards the far end of the deck from the hot tub https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087501435-9MQV53S6N6SFHV5V46O7/IMG_6971.jpg Philadelphia Ipe Deck In the original deck there was a flagstone patio that the client wanted to keep, so we stripped the original flagstone off and reset new stones. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087449255-6JH00VIRB4Y92A2PU9DN/IMG_6937.jpg Philadelphia Ipe Deck Shot of the outdoor kitchen area. Originally it was intended to have cabinets and stone countertops, but the client decided to hold off on those finishes for the time being. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087491000-6NYLMTN5SMNVX46P2SZK/IMG_6954.jpg Philadelphia Ipe Deck The main staircase and pergola https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087519495-NX0IYCSGXD0VDMFOREO6/Steps-2-CD.jpg Philadelphia Ipe Deck The pergola has a retractable canopy on it to provide shade from the summer sun. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087390241-8I4994G4U5ZTX6X8JG3B/HouseView_6925-6.jpg Philadelphia Ipe Deck The lower flagstone terrace https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087431539-K8L65DJPAWLWRQ30E89N/IMG_6919.jpg Philadelphia Ipe Deck Finished shot of the right side of the deck and terrace http://www.greengatewoodworks.com/new-gallery-35 daily 0.75 2017-08-14 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493515290564-QLZ3979WKSSG9NBDS0TH/IMG_0132.JPG Havertown Kitchen and Bath reno A client called me about this job after a pipe had burst while they were out of town. It had ruined their kitchen and a good chunk of their flooring in the adjacent rooms. Since the kitchen had to be replaced anyway, the client decided to use the opportunity to expand their kitchen into the attached one-car garage. During demolition, we discovered that the framing and subfloor under the second floor bathroom were rotten (unrelated to the kitchen leak), so that bathroom was gutted and redone also. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493515290564-QLZ3979WKSSG9NBDS0TH/IMG_0132.JPG Havertown Kitchen and Bath reno A client called me about this job after a pipe had burst while they were out of town. It had ruined their kitchen and a good chunk of their flooring in the adjacent rooms. Since the kitchen had to be replaced anyway, the client decided to use the opportunity to expand their kitchen into the attached one-car garage. During demolition, we discovered that the framing and subfloor under the second floor bathroom were rotten (unrelated to the kitchen leak), so that bathroom was gutted and redone also. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493515251584-AIUE9UV7E7IBDQW05P5I/IMG_0127.JPG Havertown Kitchen and Bath reno Before we arrived, the insurance company had already pulled up the flooring ruined by the leak. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087552192-V5FAHWYO3ZU1ULWDWDKX/IMG_9970.jpg Havertown Kitchen and Bath reno A custom set of built-in cabinets and window seat were requested by the client. We also installed prefinished hand scraped wood flooring throughout the first floor. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087552142-YCEW34GVNI0MQEHRHU0R/IMG_9973-A.jpg Havertown Kitchen and Bath reno We cut an arched doorway to provide access into the original one-car garage, which we converted into a living room and part of the new kitchen. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087553022-55Q5EI4QMF6DSCHSG12Z/IMG_9974.jpg Havertown Kitchen and Bath reno The new living room in what was once the garage https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087553074-XD8GKCU1IF5WN1HR3XG1/IMG_9990.jpg Havertown Kitchen and Bath reno The back half of the original garage space was converted into the new kitchen. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087553690-NMPSIVR056K39HKKU4VN/IMG_9996.jpg Havertown Kitchen and Bath reno A wider shot of the finished kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087553586-8V4VMHJ8KQ7PFNNZRN3W/IMG_9999.jpg Havertown Kitchen and Bath reno A new powder room just off the kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087551224-WG85CZBJ9LQ0M0S7H8M8/IMG_0004.jpg Havertown Kitchen and Bath reno Inside the new powder room http://www.greengatewoodworks.com/spring-house daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085591540-A3KEZMQOHWQOJSELD9YJ/IMG_0073.JPG Media Spring House https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085591540-A3KEZMQOHWQOJSELD9YJ/IMG_0073.JPG Media Spring House https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085591624-D6MDH9LSFRSR9PJ9OT3Q/IMG_0074.JPG Media Spring House A long-time client called up and asked me to come up with a solution to drain her constantly wet yard. After a little investigation I found a spring bubbling up underground. I came up with an idea to use this unique opportunity to create a stream and small pond instead of just installing a standard drain pipe and burying everything underground. In this picture the upper part of the stream has begun to take shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085596283-SQHBXR7B4UX9EO65UYFG/IMG_0082_1.JPG Media Spring House Installation of the liner https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085598892-1ZQ9PI2CPJOG78OH01L9/IMG_0094_1.JPG Media Spring House We brought in several tons of river rock to create the stream bed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085601555-XJ00W78Z6SCLP7Y5YS4J/IMG_0101.JPG Media Spring House Installation of the plants. We also installed several pieces of flagstone at the dam sites along the stream to create small waterfalls. These waterfalls in turn created a relaxing, babbling sound. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085604617-R4FUOUT61O09OZ9PIYUW/IMG_0110_1.JPG Media Spring House All the plants are in, and the beds are mulched. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085604100-5DZRR6ETP37ODSCFWVLY/IMG_0114.JPG Media Spring House After the mulch was installed, I began to create a small spring house that would give the stream a more definitive starting point. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085608877-SIG5YHZ47IPLFJQ0LC5P/IMG_0123.JPG Media Spring House After installing the roof rafters, I put on a cedar shake roof. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085610719-U92K5GJT5MPYQ8G6V6ZR/IMG_0149_2.JPG Media Spring House Trim and siding installed, along with a copper ridge cap https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085613558-11J34LJYM2BG48J2X2R0/IMG_0151_2.JPG Media Spring House The finished product. This was an interesting project and a little outside my normal routine but still a fun design process. Thanks to Brendan Gibbons and his guys for providing a lot of extra hands to get things done. If you're looking for a good landscaper, go to http://www.brendangibbonsco.com to get in contact with him. http://www.greengatewoodworks.com/hanging-planters daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837361213-Q948C6U4BV4EIY7P6RAQ/IMG_9713.JPG Cedar Fence & Hanging Planters I was contacted by a client looking for a custom fence with moveable planter boxes. This is the original fence that was removed to make way for the new one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837361213-Q948C6U4BV4EIY7P6RAQ/IMG_9713.JPG Cedar Fence & Hanging Planters I was contacted by a client looking for a custom fence with moveable planter boxes. This is the original fence that was removed to make way for the new one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837357308-XGMYWMX15ZUNMHHUEFU1/IMG_9703.JPG Cedar Fence & Hanging Planters I made up a couple two-sided cedar fence panels using horizontal slats secured to central stiles. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480167586170-5N1TCONON2P09IYLDWMJ/IMG_9577.JPG Cedar Fence & Hanging Planters For the planter boxes I made up custom hanger hardware in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837364465-Y5KDRLV4GTY29KMGH5RR/IMG_9764.JPG Cedar Fence & Hanging Planters Planter boxes with hardware attached https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837367255-2OODHD3MPTINL711T2H1/IMG_9887.JPG Cedar Fence & Hanging Planters Picture of the finished project. The tall end post serves as an anchor point for a sun-sail that was on back order at the time of this picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480167076258-665LYL2H6ILAK0SINQLV/IMG_9577.JPG Cedar Fence & Hanging Planters https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480167470228-VNE44WPL2OIZC5JZLMKB/IMG_9577.JPG Cedar Fence & Hanging Planters https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/582543294402433fe5ced769/58398e1bbebafb6551282fae/1480167001600/ Cedar Fence & Hanging Planters https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480167035463-R9VT7ARJJ8CADYJAI7Y5/IMG_9577.JPG Cedar Fence & Hanging Planters https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480109803511-QM3MIYAGMC4ZNQRSGWQ8/IMG_9577.JPG Cedar Fence & Hanging Planters https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480166941956-W5WY5EJ226OOIHNBTQG4/IMG_9577.JPG Cedar Fence & Hanging Planters https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837355061-28BHKCE1H75YTNQ5X3BB/IMG_9577.JPG Cedar Fence & Hanging Planters https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480109648012-4QMQT5WRYKM7ENJACKF6/IMG_9577.JPG Cedar Fence & Hanging Planters https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480109837251-2WAGDJTFXK8T8SYVXTKP/IMG_9577.JPG Cedar Fence & Hanging Planters https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480110670484-QPG9DM6CE5W7177815SM/IMG_9577.JPG Cedar Fence & Hanging Planters https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480110715919-HVCUVKFMEN98RGRQYWVR/IMG_9577.JPG Cedar Fence & Hanging Planters https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/582543294402433fe5ced769/5838b2b2ebbd1a7523056fd5/1480110843603/ Cedar Fence & Hanging Planters http://www.greengatewoodworks.com/new-gallery-30 daily 0.75 2017-08-14 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087663947-OJ0F9BDCIHR1WVD5AU0B/ali+c+panorama+1.jpeg Manayunk Kitchen This job came to me from a client with a very cramped kitchen who was looking to renovate and expand a bit. This is one of the before shots. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087663947-OJ0F9BDCIHR1WVD5AU0B/ali+c+panorama+1.jpeg Manayunk Kitchen This job came to me from a client with a very cramped kitchen who was looking to renovate and expand a bit. This is one of the before shots. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087663992-G3ENAAKJ5LD9IHHDC3OE/Ali+C+panorama+2.jpeg Manayunk Kitchen Another before shot of the kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087664430-J7N22XN1AOLC5O5LQ0WG/GreenGate-ManKitPano-2flat.jpg Manayunk Kitchen Wide angle shot of the new kitchen, showing the wine fridge in center island. We opened the wall up between the kitchen and dining room to allow for more light, better airflow, and to create a breakfast bar for casual dining. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087664709-CKO0UHIU5Y5FKH9SWBDJ/GreenGateIMG_6046.jpg Manayunk Kitchen Bamboo countertops https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087664979-5Q0SHNA93RIG3MD986ZR/GreenGateIMG_6052.jpg Manayunk Kitchen New cabinetry, counters, and appliances https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087665161-ZE3IS5BFY21F3ME9PEQL/GreenGateIMG_60201026.jpg Manayunk Kitchen Sink countertop and opening to dining room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087665558-7NZWE4XXAAISI3U5OJNB/GreenGateIMG_60301026.jpg Manayunk Kitchen Teak drainboard next to sink for drying dishes https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087665753-KPUS8ZDY8BBTE0Z0I7IV/GreenGateIMG_60321026.jpg Manayunk Kitchen The recessed area under the drainboard is sealed and has a drain line connected to the sink drain. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087664419-D08IS0MDD2DS5D210WMC/GreenGateIMG_6041.jpg Manayunk Kitchen The breakfast bar in the dining room has custom-built bamboo corbels. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087665793-JZFIXYLKBSDCSDK3GZRC/GreenGateIMG_60361026.jpg Manayunk Kitchen Looking into the kitchen from the dining room. We recessed the fridge into the wall a bit to pick up extra floor space in the kitchen. http://www.greengatewoodworks.com/new-gallery-97 daily 0.75 2018-02-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087796581-EOKT05GPSDTRQ52O77R4/Murray+Shop+renovation+-+before.JPG Shop Renovation This job came from a client I had done some work for previously. He had a small shop in his basement where he liked to work on various projects, but it was cluttered, lacking in storage and outlets, and not bright enough, so he asked me to renovate it and make it more functional. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087796581-EOKT05GPSDTRQ52O77R4/Murray+Shop+renovation+-+before.JPG Shop Renovation This job came from a client I had done some work for previously. He had a small shop in his basement where he liked to work on various projects, but it was cluttered, lacking in storage and outlets, and not bright enough, so he asked me to renovate it and make it more functional. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087794056-T3NLNAG2QCIKP7VKSATU/Murray+Shop+renovation+-+before+4.JPG Shop Renovation Here is another before shot of the original workshop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087794696-LCKHZR5H2J16N011IEHJ/Murray+Shop+renovation+-+before+7.JPG Shop Renovation One more for good measure https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087785501-D2YVY0C2839NW5NMFBYZ/IMG_9932.jpg Shop Renovation The renovated shop. I replaced the existing windows, packed out all the walls to add electrical outlets, built a dust vacuum system to aid in clean up, and added six new light fixtures. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087785159-OARSWYC5VDI1FVYFMQ6M/IMG_9933.jpg Shop Renovation I added slatwall panels to the upper portion of all the walls to create more hanging storage for tools. I also added new baseboard heaters and custom cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087785613-W5RV1VRDBS3A7K5NUYBZ/IMG_9937+CornerDoorClosed.jpg Shop Renovation I built this tall cabinet and corner shelf unit along with the countertop to create usable space around the existing file cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087785750-LCEXIUKUTK08RO96UN8G/IMG_9937+CornerDoorOpen.jpg Shop Renovation The tall cabinet opens to reveal a number of small drawers for housing small boxes of screws, nails, and other hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087786614-H0AQO4XUNBH83G3UP46H/IMG_9940.jpg Shop Renovation The dust vacuum system is housed beneath the long custom countertop by the window. The end cap of the system is removable to attach a vacuum hose for cleaning the shop floor. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087787766-QO2AX24KO4O4K9UFWW58/IMG_9943.jpg Shop Renovation Each machine has its own dust port with a blast gate that closes it off when not in use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087790221-UGVMJNTAT8B2GB05JCE3/IMG_9945.jpg Shop Renovation I designed and built these custom maple cabinets with plexiglass door panels to allow the client to see the items stored within. The floor was painted with a epoxy based garage floor paint to create an easily cleaned and stain resistant surface. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087792365-LWUCMITZDUQQBPH2YPSC/IMG_99550+LargeDoorTotalOpen.jpg Shop Renovation The tall wall cabinet provides storage for longer items like clamps and sections of pipe. All the pulls and handles on the cabinet doors and drawers are in a weathered bronze finish. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087791128-JBBVKCZ9J3QKJA9YQH2H/IMG_99550+AllDoorsClosed.jpg Shop Renovation The three doors next to the wide cabinet door are a raised panel bi-fold door system I designed and created specifically for this job. They provide access to a water shutoff and pressure relief system while not eating up unnecessary floor space. A video of them in operation can be seen at the end of this gallery. http://www.greengatewoodworks.com/new-gallery-71 daily 0.75 2017-08-16 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087877562-OUJTS567FC8ODDJSJBQQ/Hanhausen+-+garage+-+walls+poured.JPG Wayne Garage A client came to us for a garage addition on their 1920's stone home. The job eventually expanded into including a patio and pool deck for a new pool they had installed while we were working with them. Here the garage foundation walls are going in. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087877562-OUJTS567FC8ODDJSJBQQ/Hanhausen+-+garage+-+walls+poured.JPG Wayne Garage A client came to us for a garage addition on their 1920's stone home. The job eventually expanded into including a patio and pool deck for a new pool they had installed while we were working with them. Here the garage foundation walls are going in. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087877513-YNIT3B6LDIOPFUSKNUUM/Hanhausen+-+garage+-+wall+framing18.JPG Wayne Garage First floor framing https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087868097-2IDCH23HN6KBWHOVT7U5/Hanhausen+-+garage++-+roof+sheathing.JPG Wayne Garage Roof framing and sheathing going on. A new hallway was created to allow access from the second floor of the home into the addition, which created a nice breezeway underneath. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087867000-J0GP1RO9IOJ2YKH78RSZ/Hanhausen+-+garage+-+crown+installation4.JPG Wayne Garage Doorway arches and exterior trim installation https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087875523-B26YGZUM12NVAF1HVF2M/Hanhausen+-+garage+-+stone+installation2.JPG Wayne Garage We took stone from the original house that was obtained during the second floor demolition to attach the addition and used it on the exterior of the new garage to help blend it into the original structure. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087878368-RRWM2184N5FA5XI8A37U/IMG_6604-A.jpg Wayne Garage Shot of the finished exterior https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087879352-KNR80YKZVE4ULLWDR729/IMG_6703.jpg Wayne Garage Stairwell from garage bays up to the second floor room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087866036-A4A222J4LE34JIZKAPDH/2nd+Floor-A+Pano-Flat.jpg Wayne Garage Finished interior of the upstairs room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087866089-CJ1OSARZ1DULU8UX7IF7/2nd+Floor-C+Pano+Perspective-flat+crop.jpg Wayne Garage Another shot of finished interior of upstairs room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087879360-OK9R9939KOJ99STHA7JW/IMG_6707.jpg Wayne Garage The upstairs room has a great view of the pool below. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087868918-8GRWFXYPG04NUOGI09PZ/Hanhausen+-+garage+-+fireplace+blockwork9.JPG Wayne Garage Construction of outdoor fireplace for future patio https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087870838-AJAZTQ9JGSNP4CWCCEZP/Hanhausen+-+garage+-+fireplace+blockwork12.JPG Wayne Garage Blockwork completed for outdoor fireplace https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087871335-H1RHC7BKF0FSUWR25GR9/Hanhausen+-+garage+-+fireplace+finished3.JPG Wayne Garage Here, the gas fireplace unit has been installed and stone has been applied to match the garage and house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087873108-1JQDL2MYPLE8BC9QICRK/Hanhausen+-+garage+-+retaining+wall+install17.JPG Wayne Garage The blockwork for the retaining wall is in place, which separates the lower patio from upper patio/pool deck. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087875323-SHFLE59MYHBXYD37YS4L/Hanhausen+-+garage+-+wall+finished4.JPG Wayne Garage Retaining wall completed with stone applied to match garage and house https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087878743-0KNLQXQ7XG408JKOA0DH/IMG_6617.jpg Wayne Garage Finished pool deck https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087878925-0YPGL3Q3UL2FJM75WGCN/IMG_6624.jpg Wayne Garage The finished pool deck and rear of garage http://www.greengatewoodworks.com/mudroom-1 daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250463839-98EE3Q1ZCZ7IQ39MATPI/IMG_6414.JPG Chester Springs Mudroom & Pantry Fitout I was commissioned by a client for several different projects, one of which was a set of mudroom lockers with a live edge walnut bench top. This is one of three slabs I worked with, shown here after I milled it down from rough lumber and was starting to layout my cuts. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250463839-98EE3Q1ZCZ7IQ39MATPI/IMG_6414.JPG Chester Springs Mudroom & Pantry Fitout I was commissioned by a client for several different projects, one of which was a set of mudroom lockers with a live edge walnut bench top. This is one of three slabs I worked with, shown here after I milled it down from rough lumber and was starting to layout my cuts. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085398969-3KXA7EGR4ZVZVN7M2CBW/IMG_1141-42-crop.jpg Chester Springs Mudroom & Pantry Fitout Looking down the finished lockers https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085399262-4TT2F6OG9ZVMHJ9BBK1F/IMG_1147.jpg Chester Springs Mudroom & Pantry Fitout A closer shot of the live edge of the walnut bench top https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250328597-OVBD99XAEYHZL1HBXQK9/IMG_1162.jpg Chester Springs Mudroom & Pantry Fitout The wall adjacent to the lockers received custom wainscoting I milled and fabricated in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250350623-PVG6D3VQ6HW22WG9DQSH/IMG_1169.jpg Chester Springs Mudroom & Pantry Fitout A closer shot of the cubbies and the locker hardware https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250306020-6FTE6YFVNLG2VKORCT19/IMG_1135R-37.jpg Chester Springs Mudroom & Pantry Fitout A wide shot of the finished lockers https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250379415-W9JGKLYC6PZ9OEMYQNSM/IMG_1185.jpg Chester Springs Mudroom & Pantry Fitout Just off the mudroom is a pantry that I fit out as the second half of this project. The pantry has a 10-lite french door and an occupancy sensor that turns on the overhead and under-cabinet lights automatically. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250405687-GXTRL56EFW4D9F9QD29F/IMG_1174.jpg Chester Springs Mudroom & Pantry Fitout The pantry cabinets feature adjustable shelving, a maple countertop, and custom crown molding to match that of the lockers in the mudroom. No doors were added to the cabinets because they would take up too much room when opened in this small space. http://www.greengatewoodworks.com/new-gallery-5 daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084777099-SHA941RBRRVKNC40550E/IMG_2391.JPG Wayne Butler's Pantry For this project, the client gave me two antique windows to repair and turn into doors for a built-in butler's pantry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084777099-SHA941RBRRVKNC40550E/IMG_2391.JPG Wayne Butler's Pantry For this project, the client gave me two antique windows to repair and turn into doors for a built-in butler's pantry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084805579-L2O31QTBEMG225T1NDU4/IMG_2561-2.jpg Wayne Butler's Pantry The finished cabinet installed in the client's home. She opted to do the finish painting herself, so these pictures only show the primed unit. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084808591-YPDKXRZGOJDJLMS0GSBJ/IMG_2579-1.jpg Wayne Butler's Pantry In keeping with the older character of the windows, I used a sawtooth shelf system instead of the shelf pins used in more modern furniture for both the upper and lower cabinets. Each shelf sits on a small board that fits into the teeth of the side rails. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084809446-96IDJ9H0833SZ7H4KJMN/IMG_2581-1.jpg Wayne Butler's Pantry Close up of the storage area between the two cases. I made the countertop out of maple and stained it to match an existing one in the home. http://www.greengatewoodworks.com/new-gallery-57 daily 0.75 2017-08-16 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144713412-ZJH1OYSY2CIJBTLGFXAG/marino+before+panorama.jpg Malvern Addition This job was brought to us by a fellow contractor who wanted us to build the outer shell of this addition. Once it was up and weather-tight, he would complete the interior renovations. "Before" picture of original sunroom and deck during the initial stages of demolition. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144713412-ZJH1OYSY2CIJBTLGFXAG/marino+before+panorama.jpg Malvern Addition This job was brought to us by a fellow contractor who wanted us to build the outer shell of this addition. Once it was up and weather-tight, he would complete the interior renovations. "Before" picture of original sunroom and deck during the initial stages of demolition. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144651945-EUP9PS3AHQU6QT4OQQEI/Marino+-+excavation2.JPG Malvern Addition The original house didn't have a full basement, but the new addition would. This required us to excavate below the foundation of the main house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144670530-W2F8JILFPC4CMOTKNNKC/Marino+-+foundation+form+install3.JPG Malvern Addition Set up of forms for poured basement walls https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144704712-UUHJNUL7L8RCWA9J4DPG/Marino+-+underpinning+forms6.JPG Malvern Addition Underpinning forms - since we excavated below the foundation of the existing house, we now needed to support it. This was done by pouring a concrete wall in small sections underneath the existing foundation; each section is tied together with rebar to make the finished wall a solid unit. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144666163-K6S3W485GT4W9TCOL3FR/Marino+-+floor+pour2.JPG Malvern Addition Basement floor going in; the finished underpinning wall is on the left. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144668725-QJBH52OFVL01I6CJUFQG/Marino+-+floor+joists2.JPG Malvern Addition Floor deck installed https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144659497-O2FMSZ2A8OO7N7Q0D8ZV/Marino+-+exterior+shot4.JPG Malvern Addition Walls going up and roof framing https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144704497-DC2A5F5QNZ4FUCMPL8CB/Marino+-+stucco+brown+coat2.JPG Malvern Addition Basecoat for stucco application https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144637017-KT4D7WECDS2PHF53540Q/IMG_5832.jpg Malvern Addition Shot of the finished exterior https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144638555-ZUKF4SXZMHH1FVVMB9GS/IMG_5884.jpg Malvern Addition Finished shot of the copper porch roof and cupola   https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144638439-TPSB7SXDXRKGUFEUZ12L/IMG_5885.jpg Malvern Addition Closer shot of the cupola https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144637384-KCS0IQT8OYZYOFXRRJWF/IMG_5836.jpg Malvern Addition Shot of the finished porch https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144637433-N2QFKBTA3E0A8ZACMVDK/IMG_5843.jpg Malvern Addition Looking across the finished porch https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144637114-9IOJSRB50QFYSE4MPVSN/IMG_5834.jpg Malvern Addition Another shot of the finished porch http://www.greengatewoodworks.com/new-gallery-64 daily 0.75 2017-08-16 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087714999-UMIHKK1TCQ98Z0Q57YE6/317+oakwood+-+wide+exterior+front+shot3+with+columns.jpg 317 Oakwood This is a custom house we built in 2007. While the photogragh is a little drab because it was winter, it's the only time of year to see the whole house because the leaves are off the trees. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087714999-UMIHKK1TCQ98Z0Q57YE6/317+oakwood+-+wide+exterior+front+shot3+with+columns.jpg 317 Oakwood This is a custom house we built in 2007. While the photogragh is a little drab because it was winter, it's the only time of year to see the whole house because the leaves are off the trees. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087731077-NE135RVMTHVS4SQBFCM0/IMG_5101.jpg 317 Oakwood Wide shot of the kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087732117-CNVVLWSYKU014RFHL8PU/IMG_5102.jpg 317 Oakwood Brazilian granite countertops https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087736133-9GKQK55W3CID5OTEV8OV/IMG_5107.jpg 317 Oakwood Another shot of the kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087716501-LH0M6QCE27V441HS0F7F/IMG_5059.jpg 317 Oakwood Me, in the family room, during our open house. I think I was giving directions to somebody. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087718244-H5Y3D8REFHI2XPCNJMLP/IMG_5064a.jpg 317 Oakwood French pocket doors between the formal living room and the dining room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087720866-FFYG0UJKKZ7YR340WL8B/IMG_5074.jpg 317 Oakwood Staircase to the second floor https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087719895-4TJPK3M04HT7D024AKGE/IMG_5073.jpg 317 Oakwood Walnut inlay in the foyer floors https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087723808-GULWU89BRFSCUM0I1L9O/IMG_5083a.jpg 317 Oakwood Master bath shower https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087728112-I98H226JDO6OT25FY2JC/IMG_5100.jpg 317 Oakwood Front porch https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087714281-N7D944MEBJNRJH0HFJNW/317+Oakwood+-+exterior+shot+-+all+done.jpg 317 Oakwood This is probably my favorite picture of this project: the finished house and landscaping. http://www.greengatewoodworks.com/solderitsch-1413-window-seat daily 0.75 2018-02-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491613257671-H5L1PKOSG7W84BCE10WE/IMG_9970.jpg Havertown Window Seat Part of a larger home remodel, this set of built-in cabinets and window seat features overlay raised panel doors, adjustable shelves, and custom moldings. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491613257671-H5L1PKOSG7W84BCE10WE/IMG_9970.jpg Havertown Window Seat Part of a larger home remodel, this set of built-in cabinets and window seat features overlay raised panel doors, adjustable shelves, and custom moldings. http://www.greengatewoodworks.com/murray-sliding-lattice-panel daily 0.75 2018-02-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491617492119-NDI97BN69XA4ZSZGUPHX/IMG_6968.jpg Philadelphia Sliding Lattice Panel As part of a larger deck renovation, I made this sliding lattice panel that provided access under the deck for hot tub maintenance. Space restrictions would not allow me to hinge the access door like I might normally, and I didn't want to do a traditional slider setup where the panels are offset because that would not match the rest of the panels around the deck. Instead, I designed a track system that I had John Parker from The Painted Garden, Inc fabricate for me that had the access panel pass behind the neighboring panel while in use, but still allowed it to sit flush when not in use. A video of it in action is at the end of this gallery. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491617492119-NDI97BN69XA4ZSZGUPHX/IMG_6968.jpg Philadelphia Sliding Lattice Panel As part of a larger deck renovation, I made this sliding lattice panel that provided access under the deck for hot tub maintenance. Space restrictions would not allow me to hinge the access door like I might normally, and I didn't want to do a traditional slider setup where the panels are offset because that would not match the rest of the panels around the deck. Instead, I designed a track system that I had John Parker from The Painted Garden, Inc fabricate for me that had the access panel pass behind the neighboring panel while in use, but still allowed it to sit flush when not in use. A video of it in action is at the end of this gallery. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491617484925-FYWQJ4PKPK4149JXEJZL/IMG_6967.jpg Philadelphia Sliding Lattice Panel Here you can see how the access panel passes behind the neighboring panel when in use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1518276252676-I1H6LQLLCKYP9NME0CUJ/image-asset.jpeg Philadelphia Sliding Lattice Panel Sliding lattice panel operation http://www.greengatewoodworks.com/secret-door daily 0.75 2018-02-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491616789542-TC8ZLOVKTR42AYNJMI0I/CIMG0080.jpg Secret Door As part of a basement renovation I got to make this really cool secret door inside a cedar closet. I designed the entire system from scratch and built it using standard materials from the hardware store and some parts I had laying around my shop.   There are two videos next in the gallery; the first one shows a quick look inside the closet showing how it appears to be a standard cedar closet, and the second shows the secret door in operation. I took the videos with my phone at the time, so they're not the highest quality videos, but they're all I have of this particular project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491616789542-TC8ZLOVKTR42AYNJMI0I/CIMG0080.jpg Secret Door As part of a basement renovation I got to make this really cool secret door inside a cedar closet. I designed the entire system from scratch and built it using standard materials from the hardware store and some parts I had laying around my shop.   There are two videos next in the gallery; the first one shows a quick look inside the closet showing how it appears to be a standard cedar closet, and the second shows the secret door in operation. I took the videos with my phone at the time, so they're not the highest quality videos, but they're all I have of this particular project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1518275623267-PXB6GNS6GX45ZK6AH4WL/image-asset.jpeg Secret Door Video showing closet https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1518275984863-NVQJWISLXGWZOX0AZ022/image-asset.jpeg Secret Door Secret door operation http://www.greengatewoodworks.com/maryjane-bedroom daily 0.75 2018-02-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615717452-ALVCVRMDF1U865B5T163/IMG_8889.JPG Daughters Bedroom As part of my on-going personal home renovation, I made this sliding barn door window covering during the nursery preparation for my youngest daughter, The pre-made hardware at the store was outside my budget, so I made my own custom track and hangers in the shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615717452-ALVCVRMDF1U865B5T163/IMG_8889.JPG Daughters Bedroom As part of my on-going personal home renovation, I made this sliding barn door window covering during the nursery preparation for my youngest daughter, The pre-made hardware at the store was outside my budget, so I made my own custom track and hangers in the shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1518276712714-KJVOO3C1BKLN5GXOHZ4E/image-asset.jpeg Daughters Bedroom My wife operating the window cover while my older daughter provides the "ooohs" and "aaahs" http://www.greengatewoodworks.com/murray-bifold-doors daily 0.75 2018-02-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615386632-3RWE4DXQMZRFR53C0EGA/IMG_99550+AllDoorsClosed.jpg Philadelphia Bifold doors This is part of a larger shop renovation I did for a client; you can see the rest of the project here. The three doors to the left of the wide cabinet door are a raised panel bi-fold door system I designed and created specifically for this job. They provide access to a water shutoff and pressure relief system while not eating up unnecessary floor space. A video of them in operation can be seen at the end of this gallery. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615386632-3RWE4DXQMZRFR53C0EGA/IMG_99550+AllDoorsClosed.jpg Philadelphia Bifold doors This is part of a larger shop renovation I did for a client; you can see the rest of the project here. The three doors to the left of the wide cabinet door are a raised panel bi-fold door system I designed and created specifically for this job. They provide access to a water shutoff and pressure relief system while not eating up unnecessary floor space. A video of them in operation can be seen at the end of this gallery. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615386954-ARMZMO2BM36W1LAJW69F/IMG_99550+FoldingDoorsTotalOpen.jpg Philadelphia Bifold doors When fully opened the allow access to the main water shut off for the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615334349-KYNO2S8V34OMFDIH6UDG/Bifold_raised_panel_doors+copy.gif Philadelphia Bifold doors A GIF video showing the operation of the bi-fold doors. http://www.greengatewoodworks.com/kemp-kitchen-nook daily 0.75 2017-08-14 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496869977640-SOMHZ7J2W7O98BLMUUWD/IMG_5971.JPG Chester Springs Kitchen Nook I received a call from a client for several projects they had in mind. One of those was a new dining area in their kitchen. They commissioned me to create a built-in bench, a stone accent wall, and a custom live-edge table. This is the area prior to work beginning. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496869977640-SOMHZ7J2W7O98BLMUUWD/IMG_5971.JPG Chester Springs Kitchen Nook I received a call from a client for several projects they had in mind. One of those was a new dining area in their kitchen. They commissioned me to create a built-in bench, a stone accent wall, and a custom live-edge table. This is the area prior to work beginning. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496869985546-CT2ZIVO0FJSELXTLIS7U/IMG_5986.JPG Chester Springs Kitchen Nook To begin the stonework, we removed the drywall and installed tar paper and wire mesh over a plywood backing. After that, a brown coat was installed which serves as a base layer for the stone. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496869995074-FL9I6VF30510RIWPFVRZ/IMG_5992.JPG Chester Springs Kitchen Nook We used a 2" veneer stone to match some existing stone accents in the home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496869999503-QAOO6YEP417EWMER6A9X/IMG_6808.JPG Chester Springs Kitchen Nook After the stonework was complete, I began work on a built-in bench seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870006002-4CAZMTULKXQE20ENH7AD/IMG_6857.JPG Chester Springs Kitchen Nook With the bench tops on and the back panels being framed up, it begins to take shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870015562-N2Z41TNH09Y3MPYW99PC/IMG_6871.JPG Chester Springs Kitchen Nook I trimmed the bench out to match the existing trim scheme of the home and used beadboard paneling to complete the back and lower face. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870016869-KE2VPOU5FTSGFE2QWTAQ/IMG_6889.JPG Chester Springs Kitchen Nook The bench was painted with a white chalk paint and antiqued using a mix of dark and clear waxes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870524499-LOBLFFUT08QVDXCD717C/IMG_5969.JPG Chester Springs Kitchen Nook The final part of this project was fabrication of a custom dining table. The client chose this white oak flitch, shown here with me and my shop assistant. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870523385-9RUFKHVT3NQDYJ6K4LU3/IMG_6127.JPG Chester Springs Kitchen Nook Trimming the slab to length. After this I flattened it using my router sled. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870550076-C694I91UQKDYWKQG6MBH/IMG_6479.JPG Chester Springs Kitchen Nook I inlaid a piece of plexiglass in the bottom of the slab under the central hole in order to fill it in. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870567804-EKX7T2NNP8DJJFONL0PT/IMG_6520.JPG Chester Springs Kitchen Nook The client had a tree of life emblem she wanted embedded in the hole, so after I closed the bottom off with plexiglass, I installed the emblem in the middle of multiple layer of crystal clear epoxy. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870568871-UOW8NIUH8Q7VUX9GTWCC/IMG_7289.JPG Chester Springs Kitchen Nook After staining and clear coating the table, I polished it to the desired sheen. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870328981-P52OL4XI9ZAJUJ6HID6H/IMG_1190.jpg Chester Springs Kitchen Nook Wide shot of the finished project https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870331884-3A88NC8ZRSD75K1Y9J47/IMG_1250.jpg Chester Springs Kitchen Nook The finished bench seating https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870332445-OBY9O4ZRVC0A1DW68BX1/IMG_1253.jpg Chester Springs Kitchen Nook The bench tops lift up to reveal storage space inside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870329854-ESLWZFNS99X8X5XP3BCX/IMG_1197.jpg Chester Springs Kitchen Nook The finished table in its spot along with the custom cushions the client had made for the bench seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870329901-WCX83G782QFCWKQ8GO5B/IMG_1214.jpg Chester Springs Kitchen Nook Looking down the live edge of the table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870330643-5NQR7VKPB12SHHLNLWUY/IMG_1221.jpg Chester Springs Kitchen Nook The table base was fabricated by John Parker of The Painted Garden, Inc based on my design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870331689-UCU3VIU6N4H6TYK71UJT/IMG_1247.jpg Chester Springs Kitchen Nook A view of the embedded emblem https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870329035-T6T0QY7W9UAWIFKV4DV1/IMG_1188.jpg Chester Springs Kitchen Nook Another finished shot of the entire area. Through the arched window you can see the existing stone we matched for this project. http://www.greengatewoodworks.com/wine-totes daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501520907589-RGM9LH630TLF0OG0KIVC/wine.jpg Wine Totes Despite what it looks like, I'm actually working and not just drinking myself silly. My daughter's nursery school was having a fundraiser where each class put together a basket to be auctioned off. Our class's theme was "wine," and my wife asked if I could make something to hold the wine bottles, so I got to work designing a carrier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501520907589-RGM9LH630TLF0OG0KIVC/wine.jpg Wine Totes Despite what it looks like, I'm actually working and not just drinking myself silly. My daughter's nursery school was having a fundraiser where each class put together a basket to be auctioned off. Our class's theme was "wine," and my wife asked if I could make something to hold the wine bottles, so I got to work designing a carrier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501520775181-7RX7UOZCKQRFDRVVA496/IMG_2179.JPG Wine Totes I based my design on vintage tool carriers and shaped the end panels to mimic the shape of a wine bottle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501520459888-A7COFOD7ILZ4OG1GCAAC/wine+holder.jpg Wine Totes The finished pair of wine carriers ready to be auctioned off. Each one is made of solid maple with through-tenon joinery, and the bottoms are also set into grooves along the lower rails for additional strength. http://www.greengatewoodworks.com/stephanie-phillips-ipe-deck daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519910569-3GUH6FFVCV2JLJ8BI9ZU/IMG_2480.JPG Berwyn Ipe Deck This client wanted to get rid of the rear staircase that was left over from construction on their home. I worked with them on developing a design for a small ipe deck to provide a landing area outside their doors. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519910569-3GUH6FFVCV2JLJ8BI9ZU/IMG_2480.JPG Berwyn Ipe Deck This client wanted to get rid of the rear staircase that was left over from construction on their home. I worked with them on developing a design for a small ipe deck to provide a landing area outside their doors. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519910489-91WR271ZTU5V2UM73MQL/IMG_2493.JPG Berwyn Ipe Deck The main framing is installed. The open framing at the corners is where the steps will curve around. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519540363-IZ15GKQYFR4UJLE239NE/stephanie+ipe+deck+3.jpg Berwyn Ipe Deck These are the curved risers for the stairs that I made for the deck out of ipe and pressure treated framing lumber. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519913195-FVINKGX4UVQ6EDFVNGW0/IMG_2572.JPG Berwyn Ipe Deck Here, the risers and necessary framing have been installed, and I'm starting to install the decking. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519540041-BRHYI2M40O2J97MA2YRA/stephanie+deck+2.jpg Berwyn Ipe Deck The upper stair tread also serves as a border for the main area of decking. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519542284-W1GJHW6T65XEBUE03GGL/stephanie+ipe+deck+1.jpg Berwyn Ipe Deck The finished product with post wraps and railings installed. http://www.greengatewoodworks.com/solderitsch-kitchen-table-and-banquette daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503366-ORIWYH2Z1FOVGXNR8DJE/sold+1.jpg Haverford Kitchen Table and Banquette A kitchen table and built-in banquette project I completed for an existing client. The table is 46” square with a 2-1/2” thick solid rock maple top and a simple pedestal base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503366-ORIWYH2Z1FOVGXNR8DJE/sold+1.jpg Haverford Kitchen Table and Banquette A kitchen table and built-in banquette project I completed for an existing client. The table is 46” square with a 2-1/2” thick solid rock maple top and a simple pedestal base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503410-IQY8F6OJICXYSQKYULF5/Sold+2.jpg Haverford Kitchen Table and Banquette The all-white banquette base and back provide contrast to the black table base, while the matching bench tops and table top tie the two pieces together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503533-HV02NAB30E54EJDYYANZ/Sold+3.jpg Haverford Kitchen Table and Banquette The area for this breakfast nook was small, and the client had a concern about how close it would be to their existing kitchen island. I gave the table two 7” wings that fold under and lock into place to reduce its overall size when not in use. Furniture pads hidden on the bottom of the pedestal base make it a breeze to slide the table in closer to the banquette to gain more space when necessary. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503579-J0M8ZURII4NOGQPMSD1U/Sold+4.jpg Haverford Kitchen Table and Banquette The bench tops have concealed Soss hinges and open up for additional storage space inside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503664-EK690MFCGYE15KC7FV9B/Sold+5.jpg Haverford Kitchen Table and Banquette The banquette has solid rock maple tops to match the table, and a simple flat panel design on the base and back to match existing paneling in the house. At the far right side there is a recessed shelf that houses two outlets and provides an area to hide away phone chargers, etc. http://www.greengatewoodworks.com/bebe-forster-mbr-renovation daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524298880-3KCYD6DABZ4BJ4DUP3BR/IMG_1367.JPG Wayne MBR renovation Ann Forster of Ann Decker Design brought this bedroom renovation job to me. Her clients wanted to update their master bedroom with an enlarged closet and some built-ins. These are the two original closets. A new, larger closet will go in place of the left-hand closet, and the right-hand closet will have the door swing reversed for easier access. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524298880-3KCYD6DABZ4BJ4DUP3BR/IMG_1367.JPG Wayne MBR renovation Ann Forster of Ann Decker Design brought this bedroom renovation job to me. Her clients wanted to update their master bedroom with an enlarged closet and some built-ins. These are the two original closets. A new, larger closet will go in place of the left-hand closet, and the right-hand closet will have the door swing reversed for easier access. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524301868-AMZB5LS3H6D8IWQYW768/IMG_1382.JPG Wayne MBR renovation Old closet removed https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524302642-MEI7WOBGNU4L1I08IT27/IMG_1436.JPG Wayne MBR renovation New closet framed in and drywalled https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524304287-13G3NH5F4CHX034WTHXF/IMG_2501R.jpg Wayne MBR renovation Finished shot of the new closet, tall shoe cabinet, and radiator cover. The double doors on the closet were originally single doors in the home and were repurposed for this closet. I also made custom door casing and baseboards to match the existing trim scheme. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524304797-LH7DJYOF7I5G0RIOU6X4/IMG_2502R.jpg Wayne MBR renovation Shoe cabinet opened up shows lots of adjustable shelving for ample storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524304234-HL1CI3RQEBQZ61GU95JX/IMG_2500R.jpg Wayne MBR renovation The newly enlarged closet opens to reveal multiple hanger rods, a central built-in with inset drawers and adjustable shelving, and a custom shoe rack for additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524298480-NPZKX8E1CJ3AX5PL0H65/IMG_1371.JPG Wayne MBR renovation Before shot of the other side of the room. The plan called for two built-in bookshelves to connect over top of the bed, additional overhead lighting and wall sconces, and a window seat to the right. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524303563-QTGEKT1UWEYZTR88KET7/IMG_2481.jpg Wayne MBR renovation Finished shot of the right side of the bedroom. Each built-in features two inset drawers and a sawtooth adjustable shelf system. The radiator cover matches the other one on the far side of the room. The window seat opens for additional storage within. A cushion for the window seat was in the works at the time of this picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524303487-422IANA7DB5ENVU40CXL/IMG_2484.jpg Wayne MBR renovation The left side of the bedroom has a matching built-in bookshelf. The closet shown here is the original closet from the first picture with the door swing reversed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524302670-NTS8Z9VUC83Q85PSESGV/IMG_2478.jpg Wayne MBR renovation In this wide shot from the doorway, the two bookshelves frame the bed nicely. As usual, all the drawers I made for this project are solid maple with hand-cut dovetail joinery. All design and decorating work by Ann Forster of Ann Decker Design. http://www.greengatewoodworks.com/mackey-built-in-closets daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552681665-6J7X9TJLA1FDQ87VGESD/IMG_0594.JPG Gladwyne Built In Closets and Window Seat Before picture of the room. Due to a lack of storage in this 100+ year-old Gladwyne home, the client requested two large closet cabinets along with drawer bases and upper cabinets for additional storage, as well as a window seat for their daughter’s room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552681665-6J7X9TJLA1FDQ87VGESD/IMG_0594.JPG Gladwyne Built In Closets and Window Seat Before picture of the room. Due to a lack of storage in this 100+ year-old Gladwyne home, the client requested two large closet cabinets along with drawer bases and upper cabinets for additional storage, as well as a window seat for their daughter’s room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552681710-3DXIFLOI8UOMHB58URH9/IMG_0603.JPG Gladwyne Built In Closets and Window Seat After narrowing down possibilities with the client, I came up with this design to best meet their needs. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552691817-MZSXEJA6DLKSPILZ02WN/IMG_0645.JPG Gladwyne Built In Closets and Window Seat One of the assembled cases. After all the cases were finished, I began work on the drawer boxes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552706938-95Y8H8ER2W71F5DZX9A8/IMG_0749.JPG Gladwyne Built In Closets and Window Seat Drawer sides dovetailed and grooved to hold the bottom pieces https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552697192-JHJRFOD59S9MVCGR0ISX/IMG_0725.JPG Gladwyne Built In Closets and Window Seat Part of the project required me to build a plywood torsion box. Here it is without the lid. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552700526-GLHM4UAWQBONPA723YKI/IMG_0728.JPG Gladwyne Built In Closets and Window Seat ...and here it is with the lid. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552712486-7IS2MYPIPU9142L69X6Y/IMG_0790.JPG Gladwyne Built In Closets and Window Seat Lower units going in   https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552717525-2Y1CLFSIPGX6EOSMYJU8/IMG_0814.JPG Gladwyne Built In Closets and Window Seat Middle units installed, along with the center drawer unit. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552716689-98IXWXY2R9D8JUKB8SCF/IMG_0873.JPG Gladwyne Built In Closets and Window Seat Upper cabinets, baseboard, and drawers fit and installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552746558-AP6NREWMTVBPN7N6XR37/IMG_2265.JPG Gladwyne Built In Closets and Window Seat Finished shot looking across the face of the window seat. This center unit extends 2” beyond the face of the side cabinets to give the finished piece a little more visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552794499-54WQRT0VW2W5IIO1L6MV/IMG_2271-72.jpg Gladwyne Built In Closets and Window Seat The torsion box from earlier serves as a false drawer that provides a step up to the extra tall window seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552798131-811H43GRRKY0UX9EXB8U/IMG_2269.JPG Gladwyne Built In Closets and Window Seat All of the drawers have soft close slides, while the hidden step has heavy duty slides rated to 500 lbs because I overbuild everything. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552813215-CBY6G12LTM2UPNUAO49I/IMG_2278.JPG Gladwyne Built In Closets and Window Seat The client opted for these crystal knobs with a satin nickel base for their hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552746693-6XL7QWAG6F068ZR93NBA/IMG_2261-62.jpg Gladwyne Built In Closets and Window Seat Finished shot of the completed project http://www.greengatewoodworks.com/milnes-adirondack-chair daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517306760-N4IUDAY54BPVPIHSQNPT/FullSizeRender-2.jpg Devon Adirondack Chair I was working on a different job for a client when they mentioned their adirondack chair had been broken and asked me to look at it. It was damaged beyond repair, so I offered to make them a new one based on some templates I had made up a few years back. Since they were having a party coming up a few days later, I got to work immediately. Here the individual parts have been cut out and primed, and are drying in the back of my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517306760-N4IUDAY54BPVPIHSQNPT/FullSizeRender-2.jpg Devon Adirondack Chair I was working on a different job for a client when they mentioned their adirondack chair had been broken and asked me to look at it. It was damaged beyond repair, so I offered to make them a new one based on some templates I had made up a few years back. Since they were having a party coming up a few days later, I got to work immediately. Here the individual parts have been cut out and primed, and are drying in the back of my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517307034-YLJC2I0LUUE27DZW3H38/FullSizeRender.jpg Devon Adirondack Chair I assemble the chair in four sections - two arms, one back, and one base - in jigs I made up specifically for that task. Here, the four sections are assembled and painted the final color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517306806-0NBRLSIMHVI56BM9KIVS/FullSizeRender-1.jpg Devon Adirondack Chair I managed to get the chair fully assembled, touched up and delivered the morning of their party. The design of this chair is very inviting and so comfortable, you never want to get up again. http://www.greengatewoodworks.com/my-house1 daily 0.75 2026-02-13 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514216692-7JNNQX4UNFQJROYRX9EH/O6ESY8W+-+Imgur.jpg My House This gallery shows some aspects of my ongoing personal home renovation. In this writeup I’ll include pictures of various rooms throughout our home with links to galleries specific to each project. Here is the original rancher we started with, which was a kit house built around 1954. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514216692-7JNNQX4UNFQJROYRX9EH/O6ESY8W+-+Imgur.jpg My House This gallery shows some aspects of my ongoing personal home renovation. In this writeup I’ll include pictures of various rooms throughout our home with links to galleries specific to each project. Here is the original rancher we started with, which was a kit house built around 1954. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591453033170-Q1QU6GM4NTZ2LRVU6QP5/0AAE11CC-FE08-4E74-B94F-B6B347D7C193.JPG My House The house as it currently stands (June 2020). Our goal is to make it look like a 19th century stone farmhouse that would have been original to the area. We removed the original porch on the left side and turned that into living space, then added a partial second floor. The remaining 8' or so of the first floor was then shifted to the back edge of the foundation wall to create the offset look of an addition. The main center area of the house has Chester County fieldstone applied all the way around, while the remaining areas have cement board siding. I collected the stone for house by hand from neighboring properties, then had it cut down into veneer stone before it was applied by L.S. Stone Masonry. Luis and his crew did a fantastic job and I highly recommend them if you’re looking for a mason. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591453033551-CRJWADT97V1TFTWUA8ED/B5F74F19-6CC8-49AB-B027-30313B39CFAF.JPG My House Along the driveway are the three rooms we created in place of the original porch. From back to front there is a mudroom, laundry room, and greenhouse. Above those rooms and wrapping around the back of the house is a roof deck accessible from the master bedroom, with a custom railing made by JGM, Inc. Rope lighting on the roof deck and inside the ceiling of the rear covered porch provide the perfect amount of light for sitting outside on warm summer evenings. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770904722317-EW557ZZCGH80MAOZUO0R/IMG_0665+2.jpeg My House This is our mudroom, the first of the three “porch rooms” as you enter. In keeping with the feel of the original porch that was there, I installed reclaimed brick floors and a v-groove wainscoting ceiling. More pictures of this room build can be seen here. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905280715-H4C3N7Q2YMLJ6TSU0GIO/IMG_0701+2.jpeg My House Our mudroom lockers include a black walnut bench, custom crates up top for smaller items, and true Penco brand locker numbers. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770904915199-ZJMY9WPPI5UOHEHZ41SC/C3C15908-CC58-49FA-980B-F22CAF904B85.JPG-2.webp My House Our laundry room, just off the mudroom, has a black walnut countertop, large farm sink, custom cabinetry throughout, and a hidden laundry chute. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906941652-324ZRUN30VFXHP7AI01N/C592B8E8-5EEB-4629-A57D-82D75FB72CCC.JPG.webp My House The last of the three porch rooms is our sunroom that we call the greenhouse. In addition to the reclaimed brick floors and wainscot ceiling, it has stone to match the exterior of the house, custom paneling, and, naturally, plenty of plants. Ducts coming from and returning to the main section of the house allow this room to act as a passive heater, circulating warm air through the home with no moving parts. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501521603996-WOIM3P6K9Y3533RLB4WU/1217+kitchen.jpg My House Moving on to the kitchen, I made all the cabinets, doors, and drawers in my shop. Eventually there will be a peninsula along side the last cabinet on the right which will have a butcher block top and will serve as a prep area for when I cook. The countertops in the picture are temporary plywood ones. I milled rough lumber from a maple tree on our property and will turn that into wood countertops once it is dry, which should be sometime in mid-2018. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905178866-T468KJ74TZIGTP3E3KMA/Campbell%2BBuilt-In%2B2-2019%2BIMG_4507%2B-%2Blightened%2Bfloor%2Bfixed.jpg.webp My House Beyond the kitchen is our living room. I installed these built-ins as a Christmas present for my wife. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770942145055-9XZLNN4GOIWRJWOVOTDC/Screenshot+2026-02-12+at+7.20.44%E2%80%AFPM+2.png My House I installed this distressed red pine flooring throughout the first and second floors of my home to keep with the 19th century character we were going for. Red pine was widely available at the time and used in many older homes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905178786-7XD9ECKJSL223A1YZFKD/1217%2Bgirls%2Bbulit-ins3.JPG.webp My House Upstairs I installed these built-ins in my daughters’ room. Dutch the cat is a big fan of the window seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905179914-RC4NOI9PLW07A6W7N95D/IMG_8889.JPG.webp My House When my youngest daughter was born, my wife asked for a sliding window cover for her nursery. I built this using some extra wood in the shop and fabricated the hardware myself as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501521604189-CTA62GUK6JG9MT8BJ742/1217+window+trim.jpg My House Just before Christmas 2016 I installed window trim throughout the house. In this picture they still need nail holes filled and a coat of paint, but now that we had windowsills we could finally use our electric window candles for the holidays. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606146631372-EJDPWV1USA96LJX58TIR/IMG_1603.jpg My House An outside shot of all the window candles turned on. I installed outlets at each window that are hooked to a single circuit in what's known as a "holiday package." This circuit is controlled by a mechanical switch which turns them on and off automatically, along with our christmas tree lights, christmas wreaths up in the cupola windows, and a second christmas tree in the greenhouse. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905179873-4BYZRHPH8D5QZGL4ADMK/IMG_1483.JPG.webp My House For a side project, I also created this LEGO scale model of the house for my kids. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770908357191-NWEDCY0RIAX2QNEQPKVZ/IMG_1267.jpeg My House In addition to the house renovation, I also built a new workshop on my property. http://www.greengatewoodworks.com/milnes-staircase-rehab daily 0.75 2017-08-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517733838-RPWAG6L80ZTZ6QJ5FAW0/Milines+before+stairs.jpg Devon Staircase Rehab This job came to me from a client who was having a wedding reception at their home and were concerned about their existing staircase. The treads and risers had rotted out over the years and needed to be replaced. I suggested ipe for the job for its durability and rot-resistance. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517733838-RPWAG6L80ZTZ6QJ5FAW0/Milines+before+stairs.jpg Devon Staircase Rehab This job came to me from a client who was having a wedding reception at their home and were concerned about their existing staircase. The treads and risers had rotted out over the years and needed to be replaced. I suggested ipe for the job for its durability and rot-resistance. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517733916-MX1OBLBA7EMTF2H2Q3BS/Milnes+after+stairs.jpg Devon Staircase Rehab The finished job with all treads and risers replaced with solid ipe. Hidden fasteners secure the ipe to the framing below, and where the fasteners wouldn't work I used ipe plugs to conceal stainless steel screws. After sanding them flush they disappear into the overall design. http://www.greengatewoodworks.com/dempsey-sofa-table-and-nesting-benches daily 0.75 2017-08-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538982656-NKGXPQ651VQ8YK3UM0PT/IMG_8072.JPG Sofa Table and Nesting Benches A client was brought to me who had a number of old barn beams on their property. They wanted to make a simple sofa table with some nesting benches. JGM, Inc provided the bases for the benches and table. The barn wood was very rough initially, and it was delicate work to find a balance that made it pleasant to the touch without removing the patina of age the wood had acquired over the years. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538982656-NKGXPQ651VQ8YK3UM0PT/IMG_8072.JPG Sofa Table and Nesting Benches A client was brought to me who had a number of old barn beams on their property. They wanted to make a simple sofa table with some nesting benches. JGM, Inc provided the bases for the benches and table. The barn wood was very rough initially, and it was delicate work to find a balance that made it pleasant to the touch without removing the patina of age the wood had acquired over the years. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538989053-CCXYEL10UZ8V6ETI1GPF/IMG_8105.JPG Sofa Table and Nesting Benches https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538982735-7G1AZ7BXX4WUAOGPA51J/IMG_8074.JPG Sofa Table and Nesting Benches The benches store neatly underneath the table when not in use. Small furniture pads hidden under the feet ensure they are easy to move around. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538986801-S1Z4O6CALTG7MAPAQOPE/IMG_8077.JPG Sofa Table and Nesting Benches Side view of one of the benches where the original milling marks are clearly visible https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538985716-6L1FIBEHPLWVUIHYSNQM/IMG_8082.JPG Sofa Table and Nesting Benches The character of the original beams is what makes this project really stand out. http://www.greengatewoodworks.com/opie-built-in daily 0.75 2017-07-31 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514683173-JLRL8XCMGLXP5AOXCV01/Opie+built+in1.jpg In-Wall Built in This project came to me from an old college friend who was looking for a built-in cabinet to provide more storage space in his early 1900's Folk Victorian home. We worked together on a design that would provide him with the storage space he required while blending into the existing trim scheme and decor of the home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514683173-JLRL8XCMGLXP5AOXCV01/Opie+built+in1.jpg In-Wall Built in This project came to me from an old college friend who was looking for a built-in cabinet to provide more storage space in his early 1900's Folk Victorian home. We worked together on a design that would provide him with the storage space he required while blending into the existing trim scheme and decor of the home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514683070-VJXDER751QZUDANMYL9I/Opie+built+in+2.jpg In-Wall Built in The upper cabinet area provides an area for long term storage, while the drawers are for more day-to-day use. The open space at the bottom of the cabinet provides an area to store a cable box for the neighboring television. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514683076-JU43GIZ9W8ZIIK1UWSWC/Opie+built+in+3.jpg In-Wall Built in All the drawers are solid maple with hand-cut dovetail joinery to last a lifetime. http://www.greengatewoodworks.com/solderitsch-banquette-only daily 0.75 2018-02-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515726483-3RDDKDZTBYVSBM3ELF94/Sold+5.jpg Haverford Banquette only This banquette is part of a larger project that included a kitchen table; pictures of the entire project can be seen here. The banquette has solid rock maple tops to match the table I made, and a simple flat panel design on the base and back to match existing paneling in the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515726483-3RDDKDZTBYVSBM3ELF94/Sold+5.jpg Haverford Banquette only This banquette is part of a larger project that included a kitchen table; pictures of the entire project can be seen here. The banquette has solid rock maple tops to match the table I made, and a simple flat panel design on the base and back to match existing paneling in the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515726477-OOOY83BV37DNJXYMQ29T/Sold+4.jpg Haverford Banquette only The bench tops have concealed Soss hinges and open up for additional storage space inside. At the far right side there is a recessed shelf that houses two outlets and provides an area to hide away phone chargers, etc. http://www.greengatewoodworks.com/stephanie-phillips-cedar-fence daily 0.75 2018-02-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518069227-6EH9O76VOO7YVL0Q1CT6/stpehnaie+fence+7.jpg Berwyn Cedar Grid Fence I received an order for a large custom fence - about 300 lineal feet to be exact - with open-grid panels made of solid cedar. Here is some of the raw material after the initial stages of milling. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518069227-6EH9O76VOO7YVL0Q1CT6/stpehnaie+fence+7.jpg Berwyn Cedar Grid Fence I received an order for a large custom fence - about 300 lineal feet to be exact - with open-grid panels made of solid cedar. Here is some of the raw material after the initial stages of milling. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518069011-4Z2U41DVS7WIASS9OJ28/stephanie+fence+6.jpg Berwyn Cedar Grid Fence Every piece of the panels was dadoed for a half-lap joint for increased strength. My small shop started filling up with parts very quickly.   Next up is a short time-lapse video of a single panel being assembled. Showing about thirty minutes of work, it was one of 40 panels that had to be assembled, plus a few gates. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1518275293901-LVPBF2TZW0U1MOPNFFER/image-asset.jpeg Berwyn Cedar Grid Fence Cedar fence assembly time lapse https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518068728-L170A8HUPJKTBM8SQER6/stephanice+fence+5.jpg Berwyn Cedar Grid Fence Loading the panels for delivery to the site https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518068970-A9UVWI1I0M70CYURCNXA/stephanie+fence+4.jpg Berwyn Cedar Grid Fence Fence panels during installation. In order to follow the grade, we stepped the panels up as necessary, always maintaining alignment of the grids. The posts will be finished off with cedar caps painted to match, and landscaping will be used to fill in any gaps along the bottom rail. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518068351-QPAXUVXR4G6F5BT7VXAL/stehpanie+fence.jpg Berwyn Cedar Grid Fence After the masons were finished with their work, I was able to come back and install the final sections of fence that sat atop the walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518068386-RM197QLZ9CJVWJZKQQHC/stepanie+fence+gates.jpg Berwyn Cedar Grid Fence An arched gate provides the main entry area to the back yard. There is another single gate on the far side of the property, along with two sets of double gates to allow mowers and other equipment into the property. All the latches and hardware were custom made by Rocky Mountain Hardware. http://www.greengatewoodworks.com/africa-yew-slab-table daily 0.75 2017-10-20 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496189600-C2WKQAR27G4RWKHETWR3/IMG_3927.JPG Africa Yew Slab Table A client had a large yew bush cut down on their property and brought me a slab from the stump to use for an outdoor table. Since it was freshly cut, it had to dry for a year or so on my racks before it was ready for use. After it had dried, I put it on my router sled and flattened it out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496189600-C2WKQAR27G4RWKHETWR3/IMG_3927.JPG Africa Yew Slab Table A client had a large yew bush cut down on their property and brought me a slab from the stump to use for an outdoor table. Since it was freshly cut, it had to dry for a year or so on my racks before it was ready for use. After it had dried, I put it on my router sled and flattened it out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496194124-TO4EV0TULQM05SIMXIUS/IMG_4007.JPG Africa Yew Slab Table Using a chisel, I carefully removed all the bark from the slab to reveal the beautiful live edge underneath. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496192755-2YBYOZEQMW8Z0X4GA2AD/IMG_6191.JPG Africa Yew Slab Table I designed this simple metal base for the table and my friend John Parker of The Painted Garden, Inc fabricated it for me. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496284871-LIOEZTPDBBRZG0MNEML1/IMG_4210.JPG Africa Yew Slab Table After it was sanded completely smooth and had many coats of spar urethane applied, the table was ready for use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496190714-37WR136JZDNI4F5XIOXQ/IMG_4278.jpg Africa Yew Slab Table Outside in the sun, the colors really come to life. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496191221-5R2VPRL35XD28EVPC6JY/IMG_4279.jpg Africa Yew Slab Table Looking down the live edge. The creamy white of the sapwood contrasts beautifully with the red heartwood of this yew slab. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496192126-UG0PCW86KM1K0BSIX8FF/IMG_4280.jpg Africa Yew Slab Table Looking straight down at the top, it's easy to see why I call this piece the "Africa Yew Table." http://www.greengatewoodworks.com/solderitsch-outdoor-beam-table daily 0.75 2017-10-21 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543879552-41E16LZYMG69Y7HRNDTC/IMG_3940.JPG Haverford Outdoor Beam Table A client came to me with an old firewood holder they wanted to repurpose for an outdoor table. She chose some old barn beams I had in the shop to make up the table top and lower shelf. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543879552-41E16LZYMG69Y7HRNDTC/IMG_3940.JPG Haverford Outdoor Beam Table A client came to me with an old firewood holder they wanted to repurpose for an outdoor table. She chose some old barn beams I had in the shop to make up the table top and lower shelf. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543876442-JSQHL2155GXL4YEPK3LY/IMG_3942.JPG Haverford Outdoor Beam Table The beams weren't wide enough to span the table base, so i joined up two pieces for the top and two for the shelf, keeping the cut sides in the middle so that the existing patina was retained. https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/59ea8ab9dc2b4ac9dc0f15cc/59ea8d5bcd84a54dc6f0e38c/1508543835140/ Haverford Outdoor Beam Table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543902386-4YOZPGK3SKN2IA0U8V33/IMG_3983.JPG Haverford Outdoor Beam Table The cut ends of the top and shelf needed to be antiqued to match the other faces of the wood. I experimented staining it with some tea, but that didn't get the look I wanted. So I took another approach and burned them with a torch, as shown in the next video.   https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543835867-8IK4AKH1W90SMUYXG46Y/image-asset.jpeg Haverford Outdoor Beam Table - Toasting beams Antiquing some old barn wood with a torch https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543903577-SOXLQUG0OVYX0ITIJ1DB/IMG_4137.JPG Haverford Outdoor Beam Table With multiple coats of spar urethane, the table is ready to be used outside. http://www.greengatewoodworks.com/messner-entertainment-center daily 0.75 2017-10-21 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547898221-QGE559USYGKSBSSDMFTA/IMG_4134.JPG Chester Springs Entertainment Center I acquired a truckload of old house beams, ranging in age from 100 - 200 years old. I took a few of them to create shelving for an entertainment center project I was commissioned for. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547898221-QGE559USYGKSBSSDMFTA/IMG_4134.JPG Chester Springs Entertainment Center I acquired a truckload of old house beams, ranging in age from 100 - 200 years old. I took a few of them to create shelving for an entertainment center project I was commissioned for. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547894236-G18LBS3ZLFXMIPUWM4IL/IMG_4189.JPG Chester Springs Entertainment Center I resawed the beams down to the size thickness I needed for the shelves, and then got to work gluing the up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547904188-IUG6TYAOTW3PQXSQC6AW/IMG_4331+2.JPG Chester Springs Entertainment Center This is a before and after of one of the panels glued and clamped, and then after it was sanded and finished with varnish. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547908909-MVZV5DMOIS3D1UJDOQU9/IMG_4282.JPG Chester Springs Entertainment Center Another of the finished larger shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547912492-TB5V44X5KRAWKX3UF4VU/IMG_4444.JPG Chester Springs Entertainment Center The finished product in its new home. The metal framework was fabricated by JGM, Inc. http://www.greengatewoodworks.com/tommys-lunchbox daily 0.75 2017-10-21 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508549219507-MB9AOYQP2I6DWT8WDBRS/IMG_5168.jpg Tommy's Lunchbox Sometimes my custom solutions aren't just for my clients. Tommy, my helper, came to work one day without a lunch box, so I quickly made up one for him out of an old Milwaukee drill case. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508549219507-MB9AOYQP2I6DWT8WDBRS/IMG_5168.jpg Tommy's Lunchbox Sometimes my custom solutions aren't just for my clients. Tommy, my helper, came to work one day without a lunch box, so I quickly made up one for him out of an old Milwaukee drill case. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508549219419-ONMRFEFVB74RF733B9VL/IMG_5169.jpg Tommy's Lunchbox It took about 5 minutes to cut out the molded insides of the case and open up a lot more usable space. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508549220512-1WNTGPYXR4RLIS5OI4TE/IMG_5170.jpg Tommy's Lunchbox Tommy is pleased with the result. http://www.greengatewoodworks.com/parker-built-ins daily 0.75 2018-02-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626499586-W2YEW4MQEAW7YW9VNZ3O/IMG_5534.JPG Chester Springs Farmhouse MBR Built Ins A client came to me with this design they had drawn for a set of built ins for their master bedroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626499586-W2YEW4MQEAW7YW9VNZ3O/IMG_5534.JPG Chester Springs Farmhouse MBR Built Ins A client came to me with this design they had drawn for a set of built ins for their master bedroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626498600-9CQ4IW8M55LKU0Y11YT9/IMG_4099.JPG Chester Springs Farmhouse MBR Built Ins Installation of the lower cases. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626498753-XF3MF7D4WXT6I9V1F8GL/IMG_4372.JPG Chester Springs Farmhouse MBR Built Ins After the upper cases were set, doors were hung, and the end panels were installed my part of this job was complete. The clients would handle the installation of the crown molding and baseboards, as well as installing the pulls and painting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626501911-TZWZW24RG1JD0YLT98F8/IMG_5479.JPG Chester Springs Farmhouse MBR Built Ins The finished product. The client did a beautiful job with the trim and finish work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626499075-6ZJSM5P5B83GSRT4TQ77/IMG_5496.JPG Chester Springs Farmhouse MBR Built Ins Close up of the beaded face frame detail that was included to match existing cabinetry elsewhere in the house. Little details like this make a big difference in the finished product. http://www.greengatewoodworks.com/phillips-front-fence daily 0.75 2018-02-08 https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/t/5a7cbb9be4966b1a07ae6622/1510608726348/ Berwyn Cedar Grid Front Fence https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/5a0a0f3124a6942e842f7bd7/5a0a0f4a652deab98d9e5a39/1510608726348/ Berwyn Cedar Grid Front Fence https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608742531-6LSTCWZSB7ZML3ON3SM3/IMG_4768.JPG Berwyn Cedar Grid Front Fence I had previously made a cedar grid fence for a client, and they asked me to create a smaller version for the front of their property. These bundles are the milled cedar ready to be shaped into the individual grid pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608750587-ZN48EMWIFD2YMRQQN1SY/IMG_4813.JPG Berwyn Cedar Grid Front Fence I assembled the grids taller than they needed to be and then trimmed the bottom off to match the grade of the property. We took elevations on the property at the locations for each panel and used this information to calculate the necessary angle for the bottom of the panels. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608749598-4M5M5YN6DYYBSPL233CN/IMG_4825.JPG Berwyn Cedar Grid Front Fence One of the assembled panels with the angled lower rail complete. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608762060-817PEBM57689D3ETT57B/IMG_4898.JPG Berwyn Cedar Grid Front Fence All the panels laid out end to end on my driveway to check their alignment. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608761017-RB6K8SND9OCDHHNUF938/IMG_4998.JPG Berwyn Cedar Grid Front Fence Installation day with a lot of help from the guys at Doyle McDonnell, Inc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608773845-7HKD7DMMBIPEZHTKDD7Q/IMG_5196.jpg Berwyn Cedar Grid Front Fence Completed fence on the left side of the driveway. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608774501-4GVMBMMI6OUPZFX53O6M/IMG_5199.jpg Berwyn Cedar Grid Front Fence A single panel on the right side of the driveway ends into an existing garden bed. http://www.greengatewoodworks.com/garden-door daily 0.75 2020-08-29 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884762063-52TPTSMHXT80D79VWT84/IMG_0030.JPG Haverford Garden Door Client had a garden door inside a stone wall that divided the front and rear yards. It had become dilapidated over the years, so they asked me to build a new door to replicate it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884762063-52TPTSMHXT80D79VWT84/IMG_0030.JPG Haverford Garden Door Client had a garden door inside a stone wall that divided the front and rear yards. It had become dilapidated over the years, so they asked me to build a new door to replicate it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884761986-CTJVT7DJZ69UVBNW84SB/IMG_0186.JPG Haverford Garden Door I picked up a bunch of rough white oak and got to work milling it smooth. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884769723-GVNHDPI0VJEINXCP5R23/IMG_0214.JPG Haverford Garden Door The curve at the top of the door had two different radii, so I had to do some math and set up an old school trammel to create the template I needed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884769794-D0KCQS7GRJ3MLNWZEBAY/IMG_0251.JPG Haverford Garden Door Gluing up the rear frame. It's held together with mortise and tenon joinery, and I used some temporary pocket screws to help hold it tight during clamping. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884775846-F7YJU226TRNKO244SK52/IMG_0256.JPG Haverford Garden Door Next I made up a tongue and groove blank for the front face of the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884777537-XO2ZPU6KJMESVSB3GSBN/IMG_0364.JPG Haverford Garden Door I fabricated all the parts in my shop necessary to make a true divided lite window, just like in the original door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884781693-1RQVDFQZ5H64AK2RO0AY/IMG_0405.JPG Haverford Garden Door After joining the two faces and sanding them down, I primed and painted the door to match the trim color of the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884784330-SI3VUJHG4Y9D1NBANR1H/IMG_0420.JPG Haverford Garden Door Out with the old and in the the new. I pulled the old door and transferred the hinges and hardware over to the new one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884791183-HTY9SN5812B1LHXAR92R/IMG_0459.JPG Haverford Garden Door The finished door as seen from the street. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884792254-38R35K273WTANQKDZKMU/IMG_0460.JPG Haverford Garden Door I also fabricated a new cross bar that was missing from the original door, so that the latch would be functional once again. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884796090-RMOOAYHMIEHOTI72FWE0/IMG_0476.JPG Haverford Garden Door Backyard view of the finished door. http://www.greengatewoodworks.com/gallery daily 0.75 2017-11-20 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511142391888-WLIH0XMB1ZR9GE64QH2Z/summer+autumn+winter_oct+2011.jpg Gallery - test test test test test test test tetlsdjfaslkdfjas'dlkfja sdlfkjas dlfkajs dflkajs dflakjsd flaksjd flaksjd falskdjf alskdjf alsdkjf alskdjf lakjds fl https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511142391888-WLIH0XMB1ZR9GE64QH2Z/summer+autumn+winter_oct+2011.jpg Gallery - test test test test test test test tetlsdjfaslkdfjas'dlkfja sdlfkjas dlfkajs dflkajs dflakjsd flaksjd flaksjd falskdjf alskdjf alsdkjf alskdjf lakjds fl http://www.greengatewoodworks.com/new-gallery-70 daily 0.75 2017-11-20 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511145004103-95K7DRMC8MCFJUBQGFF2/IMG_4819.JPG New Gallery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511145004103-95K7DRMC8MCFJUBQGFF2/IMG_4819.JPG New Gallery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511145004399-8KLBR8UMCG5JXCN1NIGW/IMG_4820.JPG New Gallery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511145011449-B16DT2Y73L0ZGN4X4CHF/IMG_4821.JPG New Gallery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511145013167-HX52SAT3H4WHX8E8PXZ8/IMG_4830.JPG New Gallery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511145020831-XEGSJOE6K1SKI5WS8CPH/IMG_4831.JPG New Gallery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511145019438-5IRLN629WT99NBI41N2O/IMG_4864.JPG New Gallery http://www.greengatewoodworks.com/new-gallery-15 daily 0.75 2018-08-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533089548123-6R2ZKIAUAMAHOIZ3J8NL/Davis+kitchen+before+1.jpg Berwyn Kitchen Renovation A client contacted me to totally renovate their kitchen and mudroom. This is a before shot looking from the kitchen doorway towards the mudroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533089548123-6R2ZKIAUAMAHOIZ3J8NL/Davis+kitchen+before+1.jpg Berwyn Kitchen Renovation A client contacted me to totally renovate their kitchen and mudroom. This is a before shot looking from the kitchen doorway towards the mudroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533089539582-MUVAK3O9B9YQOW15EGL1/Davis+kitchen+before+2.jpg Berwyn Kitchen Renovation The other side of the original kitchen, with the doorway to the dining room on the right. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533089565844-6HQ03JO1XFWO1GDFXO98/Dining+room+Davis+before.jpg Berwyn Kitchen Renovation This is the dining room adjacent to the kitchen. Part of the renovation plan involved removing the wall between the two rooms, and replacing the dining room window with an atrium door.. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083187033-LNXKW4SW51OJYB19G0KI/IMG_3887-86.jpg Berwyn Kitchen Renovation The finished kitchen, as seen from the dining room with the wall removed. After installing the structural beam, I wrapped it in white oak to give it an antique look. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083187330-2MY1NXWIC96HRAF33LAN/IMG_3897.JPG Berwyn Kitchen Renovation Looking into the new kitchen towards the mudroom. I removed the linoleum floors and refinished the original subfloors to match the other existing floors in the house. Other work included new appliances, new cabinetry, recessed lighting, and new trim pieces to match the home’s original trim scheme. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083202428-OP9YKJGYNK365WS35PH4/IMG_3902.JPG Berwyn Kitchen Renovation Looking into the kitchen from the mudroom doorway. I reframed the original basement stairwell wall and extended it slightly to allow for more wall space for the new oven and vent hood. The clients opted to handle the painting themselves and also installed the tile backsplash. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083224202-LTDMUKZCN92F9OP4FHDZ/IMG_3916.JPG Berwyn Kitchen Renovation I installed a new glass door for the basement stairwell that let more natural light into the kitchen from an existing exterior door in the stairwell. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083201665-E2894TJDIPKPAQMXUUOM/IMG_3906.JPG Berwyn Kitchen Renovation In the original mudroom there had been a small water closet. Part of the renovation included expanding it into a proper powder room. This powder room got new fixtures, cabinetry, lighting, flooring, and a slimline radiator. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083214143-I1PPZTVBQNF224ZLVMJO/IMG_3909.JPG Berwyn Kitchen Renovation The remainder of the mudroom received a new lowboy radiator, rough-sawn floating maple shelves, refinished floors, and a new mudroom bench with a solid maple top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083215475-VZ3IGO2CR3KJ3971ZGRI/IMG_3914-13-flat.jpg Berwyn Kitchen Renovation The new atrium door that replaced the original dining room window allows more natural light into the room as well as access to the backyard. . https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083225195-BX9W42PZS0E0C8QSOMYA/IMG_3921.JPG Berwyn Kitchen Renovation One last shot looking into the kitchen from the front room of the house. http://www.greengatewoodworks.com/mid-century-stereo-console-1 daily 0.75 2018-07-31 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080201707-PFP8QUA6SG130Q2SNUEI/IMG_8077.jpg Mid Century Stereo Console This mid-century style stereo console was commissioned by a client in Boston to house his turntable and other stereo components. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080201707-PFP8QUA6SG130Q2SNUEI/IMG_8077.jpg Mid Century Stereo Console This mid-century style stereo console was commissioned by a client in Boston to house his turntable and other stereo components. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080201808-OLILQRAGLSSX77Q8VHLM/IMG_8078.jpg Mid Century Stereo Console Painted in Sun-Kissed Yellow, this piece really catches your eye. I chose oil-rubbed bronze hardware to pop against the vibrant yellow. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080202872-XPBIID234NH1B7S69125/IMG_8079.jpg Mid Century Stereo Console The doors open up for easy access to the stereo components. Hidden underneath the shelf is a power strip to neatly contain all the necessary plugs, and only a single cord comes out of the back of the console. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080202895-1DAW6TN34V8L06QL7NZD/IMG_8080.jpg Mid Century Stereo Console The top of the console opens fully as well to allow access to a turntable on the top shelf. Three holes allow for power or other cable to pass from the upper area to the lower. An additional hole in the rear of the console allows for wiring to be run out for speakers. http://www.greengatewoodworks.com/xl-farmhouse-table daily 0.75 2018-08-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080946441-TRULBLXKVQQDHKFL9JWD/IMG_3959.JPG XL Farmhouse Table This farmhouse table was commissioned by a client looking for a large sturdy table to use for family gatherings. I designed a traditional trestle table with large sturdy legs to match the 2-1/2” thick maple top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080946441-TRULBLXKVQQDHKFL9JWD/IMG_3959.JPG XL Farmhouse Table This farmhouse table was commissioned by a client looking for a large sturdy table to use for family gatherings. I designed a traditional trestle table with large sturdy legs to match the 2-1/2” thick maple top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080936437-U0XD7E5WFB8Q5UCYZR1J/IMG_3952.JPG XL Farmhouse Table The top opens up to expand the table for larger groups. The two main sections of the table top were heavy enough that traditional table slides weren’t strong enough to handle them. I designed this all-steel mechanism along with Joe Messner from JGM, Inc to handle the excessive weight. When fully extended to allow for removal of the two table leafs below, there is virtually no deflection across the top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080936412-CHW8BJR4ZVSP5VVAI3QH/IMG_3953.JPG XL Farmhouse Table With both leafs in place, the table is 48” wide by 120” long and can seat eight to ten people. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080946860-8GBPC6Z1BAE40MN1SM1J/IMG_3958.JPG XL Farmhouse Table When not in use, the table leafs store below the top on a shelf that stretches between the table legs. I designed the tops and leafs to fit together with an offset edge because I found it both challenging and visually interesting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080956058-LEJQOB7R84V3N6YDARB7/IMG_3960.JPG XL Farmhouse Table The large stretcher that runs between the bottom sections of the table legs adds additional rigidity to the overall piece. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080956303-V71GPNUOL3GT1LSNGQIA/IMG_3962.JPG XL Farmhouse Table The visually (and actually) heavy legs were lightened by the introduction of the diamond-shaped cutouts, and the overall design of the legs was based on a classic ogee profile. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080965985-5BXPF1FDIQ64UDYNCVU5/IMG_3963.JPG XL Farmhouse Table When the leafs are stored away, the table is 78” long and can seat 4-6 people comfortably. http://www.greengatewoodworks.com/curved-drawer daily 0.75 2018-08-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466774805-8TINR9IT4COJSPTCX1LH/IMG_9034.JPG Curved Drawer These are the templates I made - one for the face frame and drawer front, and the other for the front wall of the drawer box. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466774805-8TINR9IT4COJSPTCX1LH/IMG_9034.JPG Curved Drawer These are the templates I made - one for the face frame and drawer front, and the other for the front wall of the drawer box. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466777297-V2RMIE4PKS18VOYVNZJ9/IMG_9035.JPG Curved Drawer The face frame/drawer front template was based on the curve I cut into the cabinet case, and then the drawer box template was based off of that so they mated nicely. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466712661-EAOTLOCM5CVTUQJ72A5N/IMG_8476.JPG Curved Drawer Using the templates, I cut out pieces from 1x material and stacked them up as needed to get the necessary height. These two pieces are the top rail of the face frame. If you zoom in, you can see the pencil line from the template. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466712630-6HTR03UDS2U7TK5R8AH3/IMG_8477.JPG Curved Drawer Using the stand sander belt, I trimmed the pieces flush to the pencil line. To get the inner curve, I took the top cover off the sander belt to uncover the top spindle, and then used that to get close to the line. The inner curve is the outer face of the pieces, so I left those a little heavy and chased them down with a orbital sander later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466716701-0M15IS9CFYZFVBO2S0FQ/IMG_8495.JPG Curved Drawer The piece in the back is for the front wall of the drawer box, and the front piece is one of the rails from the drawer front (I think). Either way, it shows you how they look stacked up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466720157-HWQXTWB4RERWP9886OXJ/IMG_8512.JPG Curved Drawer For the stiles on the drawer front, I used 5/4 stock and held it up to the curved rail that I had trimmed to the correct approximate length. Then I put the template over top to get the curve marked. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466719983-M8HHP1NG18TAMZNP17KQ/IMG_8513.JPG Curved Drawer Some more work on the belt sander to get it close to the pencil lines. Again, I left them heavy to chase down later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466724235-25JK6VS3WZRX4QS4XXW3/IMG_8515.JPG Curved Drawer I joined the rails and stiles together with my domino jointer, using 8mmx40mm dominoes I think. I couldn't go too long with the dominoes for fear of them popping out of the face when I was cutting them in. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534467687644-PCXAGL8V7TMZ3US26QUN/IMG_9045.JPG Curved Drawer Bit of jump right now: for the drawer boxes, I was making them out of solid maple with a housed rabbet joint pinned with walnut dowels. For the curved drawer, I made up the drawers box with 3 parts (back and two sides) and a temporary short front piece so I could clamp it up and get it to the right dimensions. Then I held the curved piece over top of it and marked the joint with a pencil (visible in the next photo). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466729843-S141UVJU363FO711GA7Q/IMG_8588.JPG Curved Drawer In order to cut the joint out for the drawer box front wall, I made up 2 different jigs, this being the first of them. This one (made from scrap I had laying around), allowed me make the first couple cuts. Biggest issue with this was eyeing up the blade angle and sneaking up on the pencil lines. I’m not sure if it’s visible in this picture or not, but I marked the center line of the drawer piece so I could flip it over and get the same approximate cut on the other side. It still took some adjusting, but it got me in the right ballpark. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466733405-OPTRWSM6UXGSBO1F3FYB/IMG_8589.JPG Curved Drawer Closer shot of what I was cutting out on the first jig. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466740945-EMZC7IG567HMT50EIJLC/IMG_8593.JPG Curved Drawer This is the second jig to complete the cuts. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466740890-FL3EZLP7L43OF0X2D30H/IMG_8594.JPG Curved Drawer Close up of the piece on jig #2 before cutting it. I also added some side walls after I took this picture so I could run it through the table saw without the base coming apart. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466744078-YOP1C14O14I41F7LC78L/IMG_8595.JPG Curved Drawer After the cuts were made. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466746603-RU8XAW0HYHN6NZOOSWU8/IMG_8597.JPG Curved Drawer Top view of the finished joint. I ended up over cutting it just a stitch. Next time around I’d leave the pencil lines and chase them out by hand with a chisel. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466747800-DSR4WN56T4WGUWHXOTCK/IMG_8598.JPG Curved Drawer After the side joints were cut, I ran it through the table saw to cut in a kerf for the drawer bottom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466758081-GX4OEIB5B06OBGBLHWRE/IMG_8604.JPG Curved Drawer The drawer box dry fit https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466760980-7CCKJJSW6WZ2E69N1N5P/IMG_8605.JPG Curved Drawer Glued up and clamped. The front wall bowed in a bit with the pressure from the clamps, so I used a spreader in the middle to push it back into the correct place (using the template to get it right). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534468464280-I1JHM715VHO6NW8IR36Z/IMG_8518.JPG Curved Drawer This is the drawer front being clamped up. I used a laminate trimmer/router to cut in grooves for the center panel to sit in. The center panel was made from 1/4” plywood that I kerfed on the backside to make it easier to bend. Clamping it up was a pain in the ass. To do it again, I’d make up another jig for it to sit over top of, with the outer face facing down so I could clamp it down into position. This way worked, but it ended up skewed a bit diagonally. I was able to pull it back into position when I attached it to the drawer box, but it was just an unnecessary difficulty I’d try and avoid next time around. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466768257-WVDNEGA98SDF0YYRO8FM/IMG_9002.JPG Curved Drawer After attaching the drawer front to the drawer box, I put in the slide hardware. I use Blum Movento slides with the depth adjusters (about $50 a pair from Lee Valley. They’re pricier than others, but they have a lot of adjustments to them which makes installation a lot easier). I had bought 20” slides - they were the right length for the other square drawers, but with the curve they ended up being too long because the front hardware (orange parts in the pic) had to be back further to operate properly. Instead of ordering shorter slides and delaying everything, I just put some spacer blocks on the back of the drawer to make it work (they’re never seen unless the drawer is taken out). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466781949-XR7GKL21TYK84TVPHUYL/IMG_9038.JPG Curved Drawer This is a close up of the drawer face top rail. You can see the joints in it and the grain change, but I’m painting it so it won’t matter. If I was doing stain grade work, I’d try and find quarter sawn material all from the same board if possible to minimize grain change and color differences. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534469079625-UAZINRHGLNE0WRE3ZH0D/IMG_9039.JPG Curved Drawer This is the inside of the drawer box where you can see all the layers stacked up. This isn’t getting painted, but since it’s the inside front of the drawer I wasn't too concerned about it being seen. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466791447-0B03APOK2ABHIHRN6YG6/IMG_9042.JPG Curved Drawer Top view of the rabbet joint. I had to fit in some little shims to close up a couple gaps. This was the result of taking too much off on the table saw, and if I’d snuck up on it with a chisel I probably could’ve gotten a better looking joint. One thing to note, the front wall of the drawer box is about 3/4” thick, whereas the sides are 9/16” thick. The sides have to be 5/8” thick or less for the drawer slides I was using, and I had initially thought I’d just sand the front wall down to 9/16” as well. However, when I marked the joint, I realized I couldn't go any thinner than 3/4” or the joint wouldn't work right. It’s annoying that they’re different, but this could probably be avoided by using a different joint entirely. Dovetails would probably work okay with two pieces the same thickness, but I’d have to experiment with it to be sure. I started using this pinned rabbet joint a while back because it’s a lot faster to make in the shop and people like the walnut/maple contrast so I just instinctively used it again on this project, not realizing it was going to cause this issue later on. Again, not a big deal, just sort of annoying although I’d be shocked if anyone ever noticed it besides me. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466800830-JL2M6WJ6RE7WEHX3XADM/IMG_9049.JPG Curved Drawer Normally I pack out the inner side walls of my cases to line up exactly with my face frames and then attach the slides to the pack outs. In this case, the side walls of the case are not at the correct angle to make that work, so I glued up some 1x stock and made this little side supports. The vertical bit in the back provides extra pressure to keep the back of the side supports from lifting up when the drawer is fully extended. The side supports are glued and tacked down, but I didn’t want to rely on just that. One pain with this method was making sure the slides were parallel the whole time so they’d operate properly. Since this is a center unit flanked by other parts of the banquette, I could cut access holes in the side of the case to allow me to see inside and mark things with a pencil while moving the drawer in and out. I don’t think that’ll work for your project since I imagine the piece you’re making will be a stand-alone one, but you might want to consider mounting any hardware like this before you put the sides together. That way you could see everything you need to see and have it all set before putting the rest of the case together. http://www.greengatewoodworks.com/butcher-block-countertop-insert daily 0.75 2021-04-11 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281672859-86OA5WTKC0HVW4OQW2NV/IMG_9142.JPG Butcher Block Countertop Insert A client commissioned me to make a butcher block insert to fill a hole where a cooktop was going to be removed from their kitchen counter. I started by milling down maple into square boards and then gluing them up into these two blanks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281669073-G9J3CYOW1K9SBJZXNQO1/IMG_9139.JPG Butcher Block Countertop Insert https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281672859-86OA5WTKC0HVW4OQW2NV/IMG_9142.JPG Butcher Block Countertop Insert A client commissioned me to make a butcher block insert to fill a hole where a cooktop was going to be removed from their kitchen counter. I started by milling down maple into square boards and then gluing them up into these two blanks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281681086-SCDKGHXSZ5HK325RQNDI/IMG_9169.JPG Butcher Block Countertop Insert After the glue was set, I ran the blanks through a wide belt sander to clean them up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281685377-SSPLXQ5K7YHWYWZPFWDF/IMG_9173.JPG Butcher Block Countertop Insert Next, the blanks were cut across their width into 3” tall strips. The strips were then glued up to make the end-grain butcher block blank. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281619506-08S0PX1UHH63I0JBIN96/IMG_9218.JPG Butcher Block Countertop Insert The blank was then trimmed and shaped to allow the lower 1” of the butcher block to recess into the countertop. The edges were also rounded over and handles were cut in at either end. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281663327-EQM84Y33IZCAM2OIET7H/IMG_9191.JPG Butcher Block Countertop Insert The butcher block was finished with multiple coats of mineral oil. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281676750-T9WV0QQI5IV0OAPMAOOA/IMG_9193.JPG Butcher Block Countertop Insert The oil gives the butcher block a nice warm color and helps to seal it against water, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281689288-6IWZFLCUXKJ5D4WMEH64/IMG_9236.JPG Butcher Block Countertop Insert Installed in the client’s home. A few extra maple blocks are used underneath to hold the butcher block securely in place, while allowing for easy removal for cleaning. http://www.greengatewoodworks.com/outdoor-fireplace-mantle daily 0.75 2018-09-19 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317864500-94U3JEGJNOLWMJ7FWVMN/IMG_8231.JPG Outdoor Fireplace Mantle A landscape design firm I work with on various projects came to me with a client who wanted a mantle for their new outdoor fireplace. We decided upon one of the 200-year-old red oak barn beams I have in stock. After doing some layout to preserve the original joinery that was still intact, the next step was cutting it to length. To maintain the proper look, I used a traditional handsaw in lieu of more modern power saws. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317864500-94U3JEGJNOLWMJ7FWVMN/IMG_8231.JPG Outdoor Fireplace Mantle A landscape design firm I work with on various projects came to me with a client who wanted a mantle for their new outdoor fireplace. We decided upon one of the 200-year-old red oak barn beams I have in stock. After doing some layout to preserve the original joinery that was still intact, the next step was cutting it to length. To maintain the proper look, I used a traditional handsaw in lieu of more modern power saws. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317864186-HA1S80GHA6K8DIT59723/IMG_8233.JPG Outdoor Fireplace Mantle The freshly cut end was glaringly bright in contrast to the two centuries worth of patina on the rest of the piece, so I used a torch and a few other methods to antique it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317869722-Y9IKFLTN05L86VE8PP5Z/IMG_8235.JPG Outdoor Fireplace Mantle The freshly antiqued cut end of the beam. After the finish is applied, the end blends in seamlessly with the rest of the beam. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317870294-K5R66PEU8Q7RZQZ6DAQI/IMG_8237.JPG Outdoor Fireplace Mantle A wider shot of the trimmed beam before finishing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317828191-16H33CZEU41L01NLZEQ1/IMG_9109.JPG Outdoor Fireplace Mantle The finished beam installed on the new outdoor fireplace. The two pockets on the front face are original mortises that include the original draw bore pegs that were used to hold the tenon of a mating piece snugly in place. A portion of one of those tenons is still visible within the left side mortise. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317826404-GFMWRCTMG8D269YDM3MN/IMG_9107.JPG Outdoor Fireplace Mantle Looking down the left side of the mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317828121-Q9N32VKXH9Y02MUMRDYU/IMG_9108.JPG Outdoor Fireplace Mantle Looking down the right side of the mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317826277-LGU0ED95VOMER8621IQO/IMG_9106.JPG Outdoor Fireplace Mantle A wider shot of the outdoor fireplace and mantle. The fireplace, patio, retaining walls, and all stonework were built by Doyle & McDonnell, Inc of Berwyn, PA. http://www.greengatewoodworks.com/curved-banquette daily 0.75 2018-09-19 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387197367-G3CN9MWM8L6QSEYGR1Y6/IMG_8225.JPG Curved Banquette A client contacted me for a built in banquette project, and during our meeting I came up with an idea for a curved seat. The case pictured here is the center unit with the curve for the seatback marked out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387197367-G3CN9MWM8L6QSEYGR1Y6/IMG_8225.JPG Curved Banquette A client contacted me for a built in banquette project, and during our meeting I came up with an idea for a curved seat. The case pictured here is the center unit with the curve for the seatback marked out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387197047-07HEBAXB9Y6BNAEYKYM2/IMG_8952.JPG Curved Banquette Two additional cases flank the center one, each case with a single drawer. The struts on along the rear wall provide support to the curved back piece. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387208475-X7NHSLWN3M1GNC3OR7YM/IMG_9131.JPG Curved Banquette The bases ganged together for installation. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387214709-UUUU46S7WY0RX72FE3WR/IMG_9244.JPG Curved Banquette After the cases were secured, I bent several layers of thin plywood and secured them to the support struts shown earlier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387223162-TF8DIGW8PCTT9HQTD8J5/IMG_9257.JPG Curved Banquette With a project like this, a lot of custom templates and jigs are required to manufacture the necessary parts. This template was for the plywood seat base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387228327-U8CWT2K4K5KSMC6YM26U/IMG_9267.JPG Curved Banquette The plywood seat fit and installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387734936-GGBHSYM2VXL4TBLBRTJ3/IMG_8604.JPG Curved Banquette Each of the three units got a solid maple drawer box using housed rabbet joints pinned with walnut dowels (not visible here). This drawer box for the center unit was one of the more challenging aspects of this project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387234216-FGONNUNAZNR1E4MQA7U0/IMG_9274.JPG Curved Banquette After fitting the drawers in the cases, I installed an upper plywood cap to tie everything together and trimmed out the back wall to create a paneled look. I also bent and installed trim and baseboard pieces to tie the project into the existing trim scheme. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387237971-TE1O3A56VKT5L0Y6E9Q5/IMG_9299.JPG Curved Banquette The finished painted banquette with handles installed on the drawers. http://www.greengatewoodworks.com/fireplace-surround daily 0.75 2018-12-05 https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/t/5c07a80688251b97f04007ac/1544005070442/ Fireplace Surround https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/5c07a59070a6ad739299724c/5c07a5ce6d2a736c35ae754a/1544005070442/ Fireplace Surround https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544005143833-7JYH0XTOIIILSQ27YCDT/IMG_0174.jpg Fireplace Surround A client contacted me about creating a surround for their fireplace. After discussing some options, I came up with a design and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544005108564-SNIYERJBQKHIHA9HBPAD/IMG_0174.jpg Fireplace Surround https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544005108592-5OIFRP6WT66ZLCSMT4GK/IMG_0175.jpg Fireplace Surround The finished product has a flat panel design for the lower half, and custom horizontal wainscot paneling on the upper half to echo the existing horizontal paneling on either side of the fireplace. Custom corbels support the new mantle, and the top is finished with a large double crown. http://www.greengatewoodworks.com/cedar-fence-2 daily 0.75 2018-12-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544006017359-O9XE9X652K3T8QXBC3A9/IMG_0176.jpg Cedar Fence 2 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544006017359-O9XE9X652K3T8QXBC3A9/IMG_0176.jpg Cedar Fence 2 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544006103685-1W0DVTUZJPAIFYVRBSRH/IMG_0176.jpg Cedar Fence 2 A few years ago, I had built and installed a custom cedar fence for a client (visible on the left side of the photo. To see the full project, click here). They contacted me later to extend the fence along the other side of their property. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544006106599-2J8G4BAPRZ0TP22KJNLC/IMG_0177.jpg Cedar Fence 2 The completed matching fence, made from knotty western red cedar planks, and finished in an oil-based sealer. Offset planks allow for privacy while keeping the overall fence visually light. http://www.greengatewoodworks.com/spalted-maple-mantle daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305715458-D4GONO56RXD275NQFJP0/IMG_0196.jpg Spalted Maple Mantle This spalted maple slab, along with a couple of other pieces, was picked by a customer to use for a few projects she had in mind. This slab in particular was chosen to become a mantle in her home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305715458-D4GONO56RXD275NQFJP0/IMG_0196.jpg Spalted Maple Mantle This spalted maple slab, along with a couple of other pieces, was picked by a customer to use for a few projects she had in mind. This slab in particular was chosen to become a mantle in her home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305715709-BYRC41B4QKEU1JN2M06N/IMG_0197.jpg Spalted Maple Mantle After looking over the slab for a while, I decided upon where to make my cuts. I use the tape to layout how the main section of the mantle will look so I can get a good idea of how the grain, etc will look in the finished product. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305716481-HHPBL0OT5SP11B7I8TN2/IMG_0198.jpg Spalted Maple Mantle After trimming off the excess from the original slab, this was the piece left over for the mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305717165-K72MGTMXBZVS3NWAB7NR/IMG_0199.jpg Spalted Maple Mantle The cutoffs from the original slab were used to create a pair of these simple corbels. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305717651-OLFRYUDIXTO7RYD42LKI/IMG_0200.jpg Spalted Maple Mantle After multiple passes with a thin epoxy to fill the many wormholes in the wood, I was able to apply a varnish coat which really brings the colors in the piece to life. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305718065-D1XC4DBTACGQ0ZOV1ZPD/IMG_0201.jpg Spalted Maple Mantle The finished mantle installed in the client’s home, just in time for Christmas as per her original request. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305718572-G94A5BN0S7IQ85738TMZ/IMG_0202.jpg Spalted Maple Mantle A closer shot of the finished mantle. I was really happy with the way this project turned out. It fit the room perfectly and the colors in the wood were absolutely fantastic. http://www.greengatewoodworks.com/new-gallery-34 daily 0.75 2018-12-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045518461-XCKMBAEOXLWF8UUCO66N/IMG_0032.JPG Clamping Shop Dollies https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045518461-XCKMBAEOXLWF8UUCO66N/IMG_0032.JPG Clamping Shop Dollies https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045559839-7P0BOO65FAEBB0GLFAIT/IMG_0032.JPG Clamping Shop Dollies Sometimes I have to make up little jigs or tools to help me around the shop. I was working on a built in project the had a fairly large maple countertop, and it was a bit too heavy to move around myself safely. So I designed and built a pair of dollies to help carry it. The design allows them to automatically clamp down on the countertop as it’s lowered between the upper jaws. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045567361-4LDIBZBS057VOTIFW5F6/IMG_0046.JPG Clamping Shop Dollies The 13’ long maple countertop loaded up in the dollies. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045566749-Z74R441NRVNSB1OWL706/IMG_0048.JPG Clamping Shop Dollies Even with the snow on the ground, these little dollies made it a breeze to load up the countertop. Certainly not the prettiest things I’ve ever built, but extremely helpful in a situation like this. http://www.greengatewoodworks.com/chalkboard-cabinet-doors daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304679082-SBEGOXXH4T8CM0ANUWU9/IMG_9552.JPG Chalkboard Cabinet Doors A client contacted me about installing some pull out shelving and cabinet doors with blackboard panels in this cabinet where their refrigerator had been previously. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304679082-SBEGOXXH4T8CM0ANUWU9/IMG_9552.JPG Chalkboard Cabinet Doors A client contacted me about installing some pull out shelving and cabinet doors with blackboard panels in this cabinet where their refrigerator had been previously. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304679244-4NDL5C81WL9M5NBXSHKQ/IMG_9554.JPG Chalkboard Cabinet Doors First step was to install a floor and toe kick to match the other cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304683227-VY7X1KQFPOQ6INAC55M7/IMG_9565.JPG Chalkboard Cabinet Doors Next up was installing framework to support the shelves, and then hang the shelves themselves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304683471-400ZGP5MLO5P9IQRENJG/IMG_9566.JPG Chalkboard Cabinet Doors Each shelf pulls out fully and is made from solid maple and uses a housed rabbet joint at each corner with a walnut dowel detail. The dowels help to reinforce the joint while also giving it some visual interest. https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/5c0c379670a6ad8468731857/5c0c37c31ae6cf68ccd9ed22/1544304615490/ Chalkboard Cabinet Doors https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304632097-4EAEQNN8I9CQAFWWSP5S/IMG_9588.JPG Chalkboard Cabinet Doors After the drawers were installed, I hung and fit the doors that I had made in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304632184-Y8IUDR3GVIX3761XLSBB/IMG_9589.JPG Chalkboard Cabinet Doors A shot of the cabinet fully opened and drawers extended. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304695165-CRYV33IL5LLP9KDJ3S9X/IMG_9590.JPG Chalkboard Cabinet Doors The doors are made of solid red oak to match the other cabinets in the kitchen The center panels are painted with chalkboard paint on both sides and provide plenty of space for notes, grocery lists, etc. http://www.greengatewoodworks.com/green-gate-sign-2 daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307184510-5TH22E8JXI383JV7C8VI/IMG_9221.JPG Green Gate Sign #2 The first sign I made for outside my shop ended up getting damaged in a storm, so I decided to make another. I went with a smaller, more ornate overall design this time, and decided to go with a solid white oak sign for this one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307184510-5TH22E8JXI383JV7C8VI/IMG_9221.JPG Green Gate Sign #2 The first sign I made for outside my shop ended up getting damaged in a storm, so I decided to make another. I went with a smaller, more ornate overall design this time, and decided to go with a solid white oak sign for this one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307189928-5FM8ZDL7Y3C5B3RVGGI9/IMG_9223.jpg Green Gate Sign #2 After designing a revised logo in Photoshop, I printed it to scale and taped it on top of the white oak blank. Then I used a marking knife to trace all the lettering. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307193796-WT3TDHXZRF3P469VV0II/IMG_9231.jpg Green Gate Sign #2 After all the tracing was done, I removed the remainder of the logo printout. Then I used a trim router to carve out the letter areas so they were slightly recessed from the main face of the sign. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307221952-8W5I6IQNVTEDOL8NONL1/IMG_9372.JPG Green Gate Sign #2 After finishing with the router work, I painted the entire sign white, and then painted the raised areas a dark green. This photo was taken midway through the painting when it was still a bit patchy, and it didn’t have the outer edge color on yet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307241716-VJTLBKO3SDDBD9RKBHMQ/IMG_9533.jpg Green Gate Sign #2 For the sign post itself, I used a cedar 4x4 for the upright, and then carved out a mortise to slide the 2x4 cedar arm through. After that, I pinned the joint with two red oak dowels and rounded over the cut edges. The arm is also secured using the decorative wrought iron bar on top. The cedar post was treated with a preservative for the portion that was underground, and above ground it was sealed with a spar urethane. It was set into a small garden of ornamental grasses to protect it from the lawnmower. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544309906070-1G3F0FWM7VIY5S9P3NCD/IMG_0232.jpg Green Gate Sign #2 A finished picture of the sign out at the front of our property. http://www.greengatewoodworks.com/st-davids-built-ins daily 0.75 2019-02-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311683522-SL3A3FASYRIGX73Z5M5J/IMG_0026.JPG St. David's Built Ins https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311683522-SL3A3FASYRIGX73Z5M5J/IMG_0026.JPG St. David's Built Ins https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311689407-FNFCOT3XB2E2NVIFXLTR/IMG_0028.JPG St. David's Built Ins I was commissioned for a set of built-ins by a client. After building and priming the cases in my shop, I started installation. Here the lower cases have been set. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311693439-WXP8P7JX4T4U3A9IM19A/IMG_0034.JPG St. David's Built Ins After installing the lower column sections, I was able to make up a template for the countertop. I took that template and used it to size the maple countertop blank I had built in the shop. After sanding, staining, and finishing it, it slid into place perfectly on site. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311701106-KFM3MCWXZ98J3VZXVEKF/IMG_0037.JPG St. David's Built Ins After the countertop was installed, I could begin installation of the upper units. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311721658-N1JCR2P3IX2C9X0F8KJK/IMG_0076.JPG St. David's Built Ins Here the upper column portions have been fit and installed, and the crown and baseboard trims are complete. A mount for the television has also been installed along with a chase to bring data cables up to the TV from the lower center cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311730248-QHS1LK3OCYMUYAXUAN5W/IMG_0080.JPG St. David's Built Ins Hanging the doors and the TV. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311736222-HG5M1CI0EYOD0DYWRFA2/IMG_0110.JPG St. David's Built Ins The finished product features sawtooth adjustable shelves, beaded face frames, solid maple raised panel inset doors, and hand-made wrought-iron handles. http://www.greengatewoodworks.com/gladwyne-linen-closet daily 0.75 2019-12-22 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549033048038-GJ2OWEIGKVH1841EPS8O/IMG_0681.JPG Gladwyne Linen Closet A client in a small 1830’s home in Gladwyne had done some renovation work closing off an old stairwell opening to create closet space in the master bedroom, and as a result this small alcove was formed in the upstairs hallway. She asked me to create a linen closet to utilize the space for more effective storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549033048038-GJ2OWEIGKVH1841EPS8O/IMG_0681.JPG Gladwyne Linen Closet A client in a small 1830’s home in Gladwyne had done some renovation work closing off an old stairwell opening to create closet space in the master bedroom, and as a result this small alcove was formed in the upstairs hallway. She asked me to create a linen closet to utilize the space for more effective storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549033047129-9LAQVAX0BGZSTNLUNWHR/IMG_0679.JPG Gladwyne Linen Closet The finished linen closet. The doors and drawer fronts all have a squared off raised panel design to match the doors on either side leading to the bedrooms. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549033047124-UVUYMV28R7R8B5OZ9CFK/IMG_0680.JPG Gladwyne Linen Closet Inside the upper area is ample storage, and on top of each adjacent doorway is a small silicone bumper to keep the linen closet doors and the door trim from damaging each other when the doors are opened. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549033048182-MV1SGHIWCDX0V6LOZOEZ/IMG_0682.JPG Gladwyne Linen Closet Three large maple drawers provide plenty of storage space below. All the drawer boxes are made from solid maple with housed rabbet joints in the corners, which are reinforced by the black walnut pegs. Each drawer is on a soft close undermount slide for smooth operation. http://www.greengatewoodworks.com/minimudroom daily 0.75 2019-02-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549031943803-MSX8QYFMN3YQRL7FNHU8/IMG_0243.jpg Mini-Mudroom A longtime client asked me to create a mudroom space for them in this little corner by their front door. They liked the look of a mudroom locker built in I had done a few years back with black walnut benches and white trim work, so using that as inspiration we moved forward. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549031943803-MSX8QYFMN3YQRL7FNHU8/IMG_0243.jpg Mini-Mudroom A longtime client asked me to create a mudroom space for them in this little corner by their front door. They liked the look of a mudroom locker built in I had done a few years back with black walnut benches and white trim work, so using that as inspiration we moved forward. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032542706-K6ORAWDWZRGRQ1XTQPK1/IMG_0366.jpg Mini-Mudroom This is the finished built in. The space was too small for traditional lockers, so multi-tiered swiveling hooks were installed to maximize storage, and the area under the bench was also left as open as possible for the same reason. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032622528-6AA6W28VR6UV1L7FXX6C/IMG_0367.jpg Mini-Mudroom The back wall of the built ins has a flat panel look to mimic other trim work in the home, and the black walnut upper shelf creates additional storage for smaller items. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032624668-9X0MDBJDQH45N5U99RNE/IMG_0368.jpg Mini-Mudroom The client didn’t want a live-edge on the benches, but I was able to incorporate the lighter sapwood of the black walnut to create some visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032626525-M6S8GM6GCBCFURZMJ5A5/IMG_0369.jpg Mini-Mudroom The miter joint where the two sections come together was carefully cut so that the lighter sapwood would transition cleanly around the inside corner. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032628833-6360FGIGOZXMEF6SACB7/IMG_0370.jpg Mini-Mudroom A closer shot of the tiered hooks. Each one has 4 hooks on 3 swivels that accommodate a lot of hanging items. http://www.greengatewoodworks.com/my-own-built-ins daily 0.75 2019-02-16 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316445112-8DWLW6UDE8OXFJD17I9D/Campbell+Built-In+2-2019+IMG_4507+-+lightened+floor+fixed.jpg My Own Built Ins This is a set of built-ins I made for my personal home. Designing your own project affords the luxury of taking your time with the design. As with most of my built-ins, the countertops and doors are made from solid maple; however, there are many hidden features in this piece, born out of many discussions my wife and I had about how these built-ins would work best for our family. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316445112-8DWLW6UDE8OXFJD17I9D/Campbell+Built-In+2-2019+IMG_4507+-+lightened+floor+fixed.jpg My Own Built Ins This is a set of built-ins I made for my personal home. Designing your own project affords the luxury of taking your time with the design. As with most of my built-ins, the countertops and doors are made from solid maple; however, there are many hidden features in this piece, born out of many discussions my wife and I had about how these built-ins would work best for our family. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316443218-HCW473VSHA4W5QTXCZZD/Campbell+Built-In+2-2019+IMG_4481.JPG My Own Built Ins A closer shot showing the maple countertops and the trim details. The center cabinet sits forwards from the side units to create some visual interest. Since the upper shelving units are set back from the lower cabinets, it made for an interesting transition where they all came together, especially in the curved front edge of the countertops. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316443756-08WSZR9LISH1Q789ZAXD/Campbell+Built-In+2-2019+IMG_4489.JPG My Own Built Ins The left-side doors conceal an existing radiator behind a false cabinet front that swings open to provide access when needed. The arched baseboard lets air in to the radiator, and the open mesh doors allow heat to flow out to the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316443575-FDN59TIIGAKYKVWROBBN/Campbell+Built-In+2-2019+IMG_4487+wires+removed.jpg My Own Built Ins Here you can see how the false cabinet front opens up. When closed, a hidden magnet helps keep if firmly in place and makes the joint where the pieces come together almost invisible. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316444017-AB3SZS7UPODSQBLFWAY8/Campbell+Built-In+2-2019+IMG_4501.JPG My Own Built Ins The lower cabinet on the right side has the same mesh doors, but to keep the kids’ toys hidden, I added a dark plywood backing. Both the center and right lower units have a dark trim board hidden behind the arched baseboard to keep toys, etc. from getting lost under there. The low shelf beneath the TV helps minimize the look of the components and conceals the various cables. Outlets located near each window are split between standard outlets and our holiday light circuit for candles at Christmastime. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316447898-ADRJIU7O96CELF2Q9RDK/IMG_0914.JPG My Own Built Ins Instead of doing more traditional crown molding, we decided not to build the upper units to the ceiling so that we could carry the existing window trim across the top as a design detail. This allowed us to add another hidden feature: a long strip of dimmable LED lights hidden behind the top trim which provides a nice glow in the evenings. That glow didn’t show up well in our professional pictures taken during the day, but I managed to get a decent shot with my phone one evening. Wafer lights are concealed above each window for additional light. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316447379-3XND7WDSCCKR61NWWI1R/IMG_0054.JPG My Own Built Ins The last two photos show what we started with and where we ended up: a mish-mash of old furniture and storage units…. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316444631-PNVC4AJA4ETRX8MD5AIS/Campbell+Built-In+2-2019+IMG_4507+-+lightened+floor+fixed+-+cropped.jpg My Own Built Ins …and now a set of functional built-ins that provide all the storage and ambient lighting we need in one package. To see more pictures of my personal home, click here. http://www.greengatewoodworks.com/tree-bookshelf daily 0.75 2019-03-11 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1552267162156-45RVEQ64W18T6RVT7NAI/tree+bookshelf+rough.jpg Tree Bookshelf My daughter’s kindergarten class was having a fundraising that my wife was involved in, so she asked me to put something together for them to raffle off. The theme was “Reading” so we came up with this tree-shaped bookshelf idea. As it was a side project, I don’t have a lot of progress photos of it, but this is it in it’s rough state. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1552267162156-45RVEQ64W18T6RVT7NAI/tree+bookshelf+rough.jpg Tree Bookshelf My daughter’s kindergarten class was having a fundraising that my wife was involved in, so she asked me to put something together for them to raffle off. The theme was “Reading” so we came up with this tree-shaped bookshelf idea. As it was a side project, I don’t have a lot of progress photos of it, but this is it in it’s rough state. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1552267171778-U1PLYOVUG8KC2BUPR0LZ/Tree+bookshelf.jpg Tree Bookshelf The finished shelf with some of the books that went along with the total package people were able to win. The wide base gives it excellent stability, and the laminated design of the shelves gives them a lot of strength. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1552267179757-86TP0OJBBZJG8UY41GPS/Bluebird.jpg Tree Bookshelf I also made two small birds to go along with the bookshelf. This one is an Eastern Bluebird. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1552267165139-KITTJO133SS6NNKU81GQ/Goldfinch.jpg Tree Bookshelf The second bird is a Goldfinch. http://www.greengatewoodworks.com/small-bar-cabinet daily 0.75 2022-08-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145006422-X5OSTECS1F4Q1WONTD52/IMG_1494.JPG Small Bar Cabinet A client had this small alcove that she wanted to use for a bar cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145006422-X5OSTECS1F4Q1WONTD52/IMG_1494.JPG Small Bar Cabinet A client had this small alcove that she wanted to use for a bar cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145006639-2XBV8OVY6D4KT0V2NYZC/IMG_1497.JPG Small Bar Cabinet There had been a corner cabinet that hung over into the alcove, so I packed out the walls to create more wall space for it to sit against. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145015151-D60HNXYNAAC8X1W9GQ8E/IMG_1513.JPG Small Bar Cabinet After hanging the drywall, I got the cabinet and countertop fit into the new space. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145027520-9IJERZLJOI9FEOB7RO6O/IMG_1534.JPG Small Bar Cabinet Installation of the inset flat-panel doors. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145052091-JHGDBC7TB72DY8N3775B/IMG_1556.JPG Small Bar Cabinet The finished space with custom baseboards I made to match the existing ones, and the corner cabinet in its new home. I used hammered antiqued brass knobs for the cabinet to match the hardware on other pieces of furniture in the room. http://www.greengatewoodworks.com/spalted-maple-floating-shelves daily 0.75 2019-04-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143557614-WXGH4T6S3HM1PPAJGHSE/IMG_1281.JPG Spalted Maple Floating Shelves https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143557614-WXGH4T6S3HM1PPAJGHSE/IMG_1281.JPG Spalted Maple Floating Shelves https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143557622-FE4B90S8FWJUXCE4OPZQ/IMG_1085.JPG Spalted Maple Floating Shelves I had some left over spalted maple from this job, and the client asked me to create some floating shelves for her living room. After cutting them to rough sizes, the next step was to fill all the small wormholes with epoxy before sanding them down and coating the shelves with a wiping varnish. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143580114-1HOL7J4CXTZI9EINDCQX/IMG_1519.JPG Spalted Maple Floating Shelves I removed some small sections of the existing walls so I could slip in some framing pieces to help strengthen the shelf brackets. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143640033-JXON1ALQIMPJDL0KQD7L/IMG_1557.JPG Spalted Maple Floating Shelves The shelves installed in their final home. They are evenly spaced on either side of the tv, but the lower shelves run long to allow for placement of taller items. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143655063-K5KXBEEP6OJ1JX2JLU9U/IMG_1564.JPG Spalted Maple Floating Shelves A side view showing the depths of the shelves. http://www.greengatewoodworks.com/cedar-platforms daily 0.75 2019-04-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554146518469-CKE3OYUOP9USE13NWPKW/IMG_1333.JPG Cedar Platforms https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554146518469-CKE3OYUOP9USE13NWPKW/IMG_1333.JPG Cedar Platforms https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554146525723-Q06J7JMDQA7DBQW2J8O5/IMG_1336.JPG Cedar Platforms I got an unusual request from a long time client to make up some cedar platforms for an outdoor space at her vacation property. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554146562328-F85TSWR5BPGPG0Z5XTZH/IMG_1341.JPG Cedar Platforms One of the completed platforms They’re all made from tight knot wester red cedar wrapped around a pressure treated frame and secured with stainless steel screws. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554146595511-RL6OCX51K6VQFZWKN8IJ/IMG_1348.JPG Cedar Platforms The five completed platforms. They will serve an a platform for a tent or for kids to play on. Each one has stainless steel hardware to link them together securely, and they are notched to drop into an existing wooden framework at the property. The client opted to oil them herself, so I left them sanded and ready to be finished. http://www.greengatewoodworks.com/steve-morrisons-batmobile-bed daily 0.75 2020-01-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288797557-R4APK9JBC99VX8LV1G96/IMG_1272.JPG Steve Morrison's Batmobile Bed Today (June 13, 2019) I can reveal a secret project I’ve been working on for the past few months: a Batmobile bed I made for Steve Morrison of The Preston and Steve Show on 93.3 WMMR as a surprise for his birthday. Steve is fairly obsessed with superheroes, and Batman in particular. One day they were talking on-air about how he should really have a Batmobile bed, so I wrote in and offered my services. After sketching up a few different ideas based on this toy model, I settled on one and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288797557-R4APK9JBC99VX8LV1G96/IMG_1272.JPG Steve Morrison's Batmobile Bed Today (June 13, 2019) I can reveal a secret project I’ve been working on for the past few months: a Batmobile bed I made for Steve Morrison of The Preston and Steve Show on 93.3 WMMR as a surprise for his birthday. Steve is fairly obsessed with superheroes, and Batman in particular. One day they were talking on-air about how he should really have a Batmobile bed, so I wrote in and offered my services. After sketching up a few different ideas based on this toy model, I settled on one and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288790018-LW5UEJ0Z1FLYZ3SQ4QCL/IMG_2289+-+with+watermark.jpg Steve Morrison's Batmobile Bed Here is the completed Batmobile bed in my shop. Based upon the Batmobile from the original 1960’s Adam West TV series, it has working headlights, Bat-rays on the front of the car (those yellow lights next to the headlights), a rocket booster in the rear, and a “P+S” Bat-signal that shines on the ceiling. Sized for Steve’s queen-sized Sleep Number mattress, it measures 11’-6” long by 5’-10” wide. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288780404-9Y5PFUK3YIGDCN88BNN9/IMG_2281+-+with+watermark.jpg Steve Morrison's Batmobile Bed A closeup of the Bat logo on the side rail of the bed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288785982-DLJKLMKN3HYG3WZM9CQ9/IMG_2285+-+with+watermark.jpg Steve Morrison's Batmobile Bed A close up shot of the back of the car and the rocket booster. https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/5d001de47fc15e0001b4e0b6/5d00222d33d71d0001b21a49/1572188324141/ Steve Morrison's Batmobile Bed - Batmobile Rocket Booster A video of the rocket booster in action. A fan and some orange ribbon bring it to life. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288785754-3PGP8FM6R0IQCGF0L5VS/IMG_2284+-+with+watermark.jpg Steve Morrison's Batmobile Bed Red LEDs inside the rocket booster give it a warm glow. The license plate is a copy of the one on the original 1960’s Batmobile. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288782802-0KMJQKL7T8GP2XS3CJ08/IMG_2282+-+with+watermark+on+side.jpg Steve Morrison's Batmobile Bed Me, holding a piece of plywood to demonstrate the Bat-signal in action. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288787284-T0SM1YGCQ3Z230G12CVH/IMG_2286+-+with+watermark.jpg Steve Morrison's Batmobile Bed A close up shot of the headlight assembly and the Bat-ray. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288789744-0KHV80OBVDCQ8KRGEBPA/IMG_2288.+-+witih+watermark.jpg Steve Morrison's Batmobile Bed Here is another wide shot of the completed bed. This was a really fun project, and I’d love to make more like it in the future, so contact me with your exotic bed ideas, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1567433111882-XQZQLV35G5JXSZJDHMRY/Steves-Batmobile-Bed-Surprise-25.jpg Steve Morrison's Batmobile Bed https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1567433154608-KM9XMIT2GPTA3ZUGD9U1/Steves-Batmobile-Bed-Surprise-36.jpg Steve Morrison's Batmobile Bed Steve taking a test drive. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1567433158706-1A3QY1NT9OQU2FLZYY33/Steves-Batmobile-Bed-Surprise-33.jpg Steve Morrison's Batmobile Bed Steve and I in studio. Below is a video of the on-air reveal from Preston & Steve’s Facebook page. http://www.greengatewoodworks.com/narberth-built-in-closets-and-window-seat daily 0.75 2019-12-09 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574216461073-2RKNPU4PBRAFVEK4G6AX/IMG_8964.JPG Narberth Built in Closets and Window Seat A client contacted me to create a built-in window seat and a pair of storage cabinets for this unique space in their daughter’s room. This was the space before I started. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574216461073-2RKNPU4PBRAFVEK4G6AX/IMG_8964.JPG Narberth Built in Closets and Window Seat A client contacted me to create a built-in window seat and a pair of storage cabinets for this unique space in their daughter’s room. This was the space before I started. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574216440330-ZEUEZA53Z2NDLQMTXWV3/59518971444__10FE5155-E941-4492-BEC6-42E4C11F195E.JPG Narberth Built in Closets and Window Seat https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574216462642-YLLR0GVPYKHWIF6NPP1T/59518971444__10FE5155-E941-4492-BEC6-42E4C11F195E.JPG Narberth Built in Closets and Window Seat After building and priming the cases in my shop, I took them to the site and installed them. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574216466642-X9XZN0G60HQL5K00CM9G/IMG_9051.JPG Narberth Built in Closets and Window Seat Next up was fitting and hanging the doors and drawers. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1575923619263-OCC3YWBW5JDE1Y57D2NA/9CE681E8-6F46-428F-9499-926C0659FB68.JPG Narberth Built in Closets and Window Seat A picture of the finished project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1575923619205-LLCNUY1NFTDL5EU8GI8K/DD060E0E-253F-4E83-8B9D-BCC86B34B90F.JPG Narberth Built in Closets and Window Seat The left side cabinet provides storage for bins and smaller items, while the right side cabinet provides hanging storage for clothes. http://www.greengatewoodworks.com/mothers-day-birds daily 0.75 2019-11-22 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574446097617-PJNL64MU06Y7XI6GG6BG/IMG_1624.JPG Mother's Day Birds After I had made this bookshelf for my daughter’s kindergarten class fundraiser, the teacher asked me about making some more birds for another project. Using plywood scraps from my Batmobile Bed project, I laid out as many birds as I could using a template i had made previously. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574446097617-PJNL64MU06Y7XI6GG6BG/IMG_1624.JPG Mother's Day Birds After I had made this bookshelf for my daughter’s kindergarten class fundraiser, the teacher asked me about making some more birds for another project. Using plywood scraps from my Batmobile Bed project, I laid out as many birds as I could using a template i had made previously. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574446113457-DDXUOR84L79AUL8QOULJ/IMG_1639.JPG Mother's Day Birds Using my bandsaw, I cut out all the pieces slightly larger than the patterns I had drawn. After this I joined up 2 pieces to make each bird, then glued and clamped them together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574446097465-CFHUKYNRTZZ9II0ZLO26/D527B441-B202-4162-86BF-1A50DE4DB99E.JPG Mother's Day Birds The sanded birds in a box, ready to be delivered. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574446191548-XFI1PM82I9AECL35Z72Q/IMG_2339.JPG Mother's Day Birds A few weeks later the kids had painted the birds up and they were ready to be presented to all the Moms. http://www.greengatewoodworks.com/standup-paddleboard daily 0.75 2026-02-11 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380300762-MTBPSEI3DUT0QBM8AKCM/IMG_0298+2.JPG Stand-up Paddleboard Back in 2016, I decided to make myself a wooden stand-up paddle board because I wanted one and it would also be a challenge to make something new. I did some research online and found that Paulownia, considered a weed tree in our area, is one of the best woods for this sort of project. After searching around a bit, I found a place where I could get a few Paulownia logs and had them delivered to my house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380300762-MTBPSEI3DUT0QBM8AKCM/IMG_0298+2.JPG Stand-up Paddleboard Back in 2016, I decided to make myself a wooden stand-up paddle board because I wanted one and it would also be a challenge to make something new. I did some research online and found that Paulownia, considered a weed tree in our area, is one of the best woods for this sort of project. After searching around a bit, I found a place where I could get a few Paulownia logs and had them delivered to my house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380301839-AZXYDO9MTBJALFSYQV5V/IMG_0301.JPG Stand-up Paddleboard The first step was to mill the logs with my alaska mill to cut them into thick planks. Then they were stacked and set aside to dry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380307027-OAAMLLQ2VGD6CCPVTWAP/IMG_6952.JPG Stand-up Paddleboard Three years later in August of 2019, the wood was finally dry enough to use. It takes about a year per inch of thickness to dry, so I knew what I was in for from the start with this project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380308749-JJOZCODCYXE39V9D7A9J/IMG_7001.JPG Stand-up Paddleboard Using 3/4” plywood, I made up a rocker template that was the approximate profile of the paddle board. That was then used to mark out pieces to be cut out from the larger planks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380314741-7MBWU4CJB2NU2NFDZ7OE/IMG_7324.JPG Stand-up Paddleboard After cutting out enough pieces, I tacked them together into a large blank. All the boards were screwed together except for the center joint which was lightly glued. This was the best way to assemble the blank because it will need to be disassembled in a later stage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380317775-PNQ0DKQHNCDUQGBTXX8Z/IMG_7335.JPG Stand-up Paddleboard Using a template I found online, I laid out the overall shape of the paddleboard. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380319408-WX3QZHVD3LEX2M42CHBV/IMG_7338.JPG Stand-up Paddleboard I used a jigsaw with an extra long blade to trim off the excess material, and at that point it really started looking like something. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380321442-P20SDSS88LHT7E73BGFH/IMG_7346.JPG Stand-up Paddleboard The next step was to shape the rails of the board using a power planer. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380323841-MDL9NBDI8N0ML4207ERU/IMG_7355.JPG Stand-up Paddleboard After the rails were shaped, I used a random orbital sander to sand the blank down to a rough shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380324506-AAEGBO8CMFTU36P7F0X9/IMG_7498.JPG Stand-up Paddleboard Next I carefully broke apart the center joint of the blank (the one that had a small amount of glue holding it together). After that I removed the screws holding the rest of the blank together and separated the individual boards. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380329104-NB9IGW3XID0IU1GVDUZV/IMG_7504.JPG Stand-up Paddleboard I marked each board with a sharpie to show where material could be removed to reduce the overall weight of the paddleboard. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380334657-SWNZCE15XJRK6IRM1V34/IMG_7512.JPG Stand-up Paddleboard This was the end result after I removed the interior material. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380337732-TCNASUIMNPE58DW8S2GY/IMG_7513.JPG Stand-up Paddleboard The chambers of each board were offset from the next board to create one large chamber inside the paddleboard, while leaving enough vertical “posts” inside the chamber for structural support. Areas for a recessed handle and finbox were left solid so there was an area to mount them in later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380342128-RO82KP9CREBPAZDZ9WWX/IMG_7533.JPG Stand-up Paddleboard After chambering each board, I glued them back together and clamped up the entire assembly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380342639-R70UQ9AK52Q0W9W0GOSE/IMG_7717.JPG Stand-up Paddleboard Once the glue had dried, I sanded the blank down to it’s final shape. The dark strip on the bottom of the board in this picture is a low area that had to be stained and filled with epoxy prior to final sanding and staining due to a natural defect in the wood. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380346358-94Z66M1A29ZWON5832WS/IMG_7718.JPG Stand-up Paddleboard After a few coats of stain, the paddleboard was ready to be fiberglassed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380351971-P6P98TK7JR7XVBDYF5EF/IMG_8140.JPG Stand-up Paddleboard Prior to applying the fiberglass, I installed the finbox in the bottom and a recessed handle in the top (shown here masked off with green tape). I also wanted to add in my company logo, so I printed it out on rice paper which will turn clear under the fiberglass coat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380353553-ZOEZGA78FZGTOPLK9ZLF/IMG_8141.JPG Stand-up Paddleboard This was taken after the first fiberglass coat, and you can see how the rice paper disappeared exactly as planned. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380358003-FUA6LNB1PUHF9MEUKUGR/IMG_8161.jpg Stand-up Paddleboard A close-up shot of my logo on the paddleboard, taken after multiple epoxy coats and some final sanding. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380361533-BSKE717A0PB3MS6QT63W/IMG_8230.JPG Stand-up Paddleboard After installing the fin in the finbox, it was time to test it out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380367975-6SUELK75DXPWROV5O18L/IMG_8401.JPG Stand-up Paddleboard Fortunately I have some friends nearby with a pool who were willing to let me do a “test float” to make sure everything worked properly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380367234-ZAZJDWGI613HAX7U7URN/IMG_8399.JPG Stand-up Paddleboard Another picture from the test float. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380293350-NW7EM4MWCF567POP8KXU/BBE280FF-D5E6-4AEF-8BC4-AE144208D055+2.JPG Stand-up Paddleboard Overall, this was a very fun and challenging project and I’m looking forward to many years of taking this out on our local lake for my morning exercise. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770838564944-IGFGF34WT59FV6QGUBWR/IMG_1514+2.JPG Stand-up Paddleboard This is a photo of me out on the paddleboard getting my morning exercise one very foggy morning in July of 2025, taken from the western shore of Marsh Creek State Park by Ed Harding. http://www.greengatewoodworks.com/lego-house daily 0.75 2019-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523539712-C4HNMTIZO4HT9BQHI4ZJ/IMG_1483.JPG LEGO House This one is a little different than my normal projects. I’ve been playing with LEGOs since I was a kid, and now my kids are into it too, which is good because it gave me an excuse to create this scale model of our house “for the kids to play with.” https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523539712-C4HNMTIZO4HT9BQHI4ZJ/IMG_1483.JPG LEGO House This one is a little different than my normal projects. I’ve been playing with LEGOs since I was a kid, and now my kids are into it too, which is good because it gave me an excuse to create this scale model of our house “for the kids to play with.” https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523538099-NJTXVV79E36IVKY3K89V/IMG_1482.JPG LEGO House https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523535030-J4WWZQS3YPS1IPVEQMKA/IMG_1479.JPG LEGO House https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523744207-8ZKE0M6Y2MCC91VU7SUB/1D3EF40A-C65C-4B4D-9378-8B7F822F13F1.JPG LEGO House https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523529274-FTLZWQQKDVKQTBHJZXBL/IMG_1475.JPG LEGO House I hinged the front wall of the house so it could open up like a doll house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523527788-INS0139I4Y1UFT0FX60R/IMG_1472.JPG LEGO House I also made up LEGO figures for my wife and I, and both the kids. http://www.greengatewoodworks.com/narberth-bedroom-builtins daily 0.75 2019-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528947404-5WX8KSIDMGWMUA0ONRCG/IMG_8750.JPG Narberth Bedroom Built-ins While I was building these living room built-ins, the client asked me to also make a set for their master bedroom to provide additional storage for their extensive book collection. Originally this wall was blank except for a dated radiator cover. In this picture, the radiator cover has been removed and the lower cabinets installed. Normally I build my cabinets in the shop and attach the face frames there prior to installation, but in this case the stairwell access to this room was so narrow I had to bring the cabinet cases up in pieces and assemble them in place, and then attach the face frames later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528947404-5WX8KSIDMGWMUA0ONRCG/IMG_8750.JPG Narberth Bedroom Built-ins While I was building these living room built-ins, the client asked me to also make a set for their master bedroom to provide additional storage for their extensive book collection. Originally this wall was blank except for a dated radiator cover. In this picture, the radiator cover has been removed and the lower cabinets installed. Normally I build my cabinets in the shop and attach the face frames there prior to installation, but in this case the stairwell access to this room was so narrow I had to bring the cabinet cases up in pieces and assemble them in place, and then attach the face frames later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528948019-ALKMVFPYFDX3RBLNMLU5/IMG_8774.JPG Narberth Bedroom Built-ins Here, the face frames have been installed, along with the new radiator cover and maple countertops. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528955048-LXA93AAMY3Q7763GIRH2/IMG_8776.JPG Narberth Bedroom Built-ins The upper cabinets installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528973863-O3M2RH9UKT8GZDZ98B33/IMG_8935.JPG Narberth Bedroom Built-ins After the trim was installed, it was ready for final painting and touchups. This unit also required custom crown molding to match the existing trim, so I fabricated that in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528997920-NTFCR4CA7AG9F3QX12Q3/IMG_9090.JPG Narberth Bedroom Built-ins The finished product. The lifted baseboards have a darkened board concealed behind them to keep any small items from getting lost back there, except for the center area. That central area is left open to allow air to flow in to the radiator so it can be heated. http://www.greengatewoodworks.com/narberth-living-room-builtins daily 0.75 2019-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527743071-R9ECNHBJGVRH6T5USLV5/IMG_8742.JPG Narberth Living Room Built-ins This client’s living room wasn’t used much by the family because it was a dim space. There was only a single overhead light, and most of the natural light was blocked by a large wrap-around porch. They also had an extensive collection of books they needed storage space for, so I came up with a plan to address the different issues. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527743071-R9ECNHBJGVRH6T5USLV5/IMG_8742.JPG Narberth Living Room Built-ins This client’s living room wasn’t used much by the family because it was a dim space. There was only a single overhead light, and most of the natural light was blocked by a large wrap-around porch. They also had an extensive collection of books they needed storage space for, so I came up with a plan to address the different issues. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527746908-3VXUDGFTOBD2EBOXD0HL/IMG_8746.JPG Narberth Living Room Built-ins The installed lower cabinets. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527756049-WEXZ830NIPMD6F6S3FA4/IMG_8806.JPG Narberth Living Room Built-ins After I had fabricated and finished the maple countertops, I installed the upper units. Next up was the trim and finishing touches. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527738860-C0S7VADB0PE4P5YFX0UL/FD176326-6A86-416F-A0F9-9D5790176EA5.JPG Narberth Living Room Built-ins The finished project features custom crown molding to match trim in the home, chamfered columns, inset raised panel maple doors, and lifted baseboards. Darkened boards behind the baseboards make sure nothing gets lost underneath. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527738711-VDXH2D1J2SXKPQRX5NHN/E05AD183-C83D-4076-B716-3B253FA5AB14.JPG Narberth Living Room Built-ins LED strip lights under each shelf and along the top of the unit add extra light to the room, making it a far more usable space. http://www.greengatewoodworks.com/lionville-builtins-banquette daily 0.75 2019-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522431794-781OVIYMT5F2N3OQ32G3/IMG_0847.JPG Lionville Built-ins & Banquette A client asked me to build a long banquette for a seating nook in an area off their kitchen, as well as an adjacent table cabinet for storage. After coming up with a design, I got to work fabricating in my shop. Here you can see the lower units installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522431794-781OVIYMT5F2N3OQ32G3/IMG_0847.JPG Lionville Built-ins & Banquette A client asked me to build a long banquette for a seating nook in an area off their kitchen, as well as an adjacent table cabinet for storage. After coming up with a design, I got to work fabricating in my shop. Here you can see the lower units installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522337459-GXBF23NT1D174JBWCVCZ/IMG_7822.JPG Lionville Built-ins & Banquette Since I do all my own work, and work alone, photos of me working are somewhat few and far between. The client took this one of me while I was filling nail holes after fitting the cabinet doors. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522391565-CRCMNFIJ1DC1H6V3LJF4/IMG_1011.JPG Lionville Built-ins & Banquette Here you can see the split top on the banquette installed and opened. Inside there is plenty of room for storage of larger seasonal items. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522185474-WM1PQILY5CCJCSL7YO5R/E78D6DCA-8BC9-4580-8A18-95AAB73C11CF.JPG Lionville Built-ins & Banquette The finished banquette. The client planned to get cushions made for the top after I completed my work, so I set the height of the banquette top to account for the thickness of the future cushions. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522185280-JE1K2BOPID6B1YCC4NLO/A447BDC4-99F9-4B4B-A0EB-35BB94064D6C.JPG Lionville Built-ins & Banquette A photo of the completed storage cabinet. The center stile on the upper portion helps to reinforce and strengthen the shelves. http://www.greengatewoodworks.com/berwyn-pergola daily 0.75 2019-11-22 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383472313-8OK0WZ3UU0HBKTMU74IU/IMG_7664.JPG Berwyn Pergola A job came to me to create an outdoor pergola that was designed by Hess Landscape Architects. I ordered these western red cedar boards to fabricate the project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383472313-8OK0WZ3UU0HBKTMU74IU/IMG_7664.JPG Berwyn Pergola A job came to me to create an outdoor pergola that was designed by Hess Landscape Architects. I ordered these western red cedar boards to fabricate the project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383449910-MC3BENR8I1GGE30YE9PN/8E173500-E54A-4FD7-9D18-118F5285DB51.JPG Berwyn Pergola The pergola contained multiple arches all based on a central point, so I made up a simple plywood trammel that would allow me to lay out all the arches at once to make sure they all fit together properly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383449150-YR922R9SMFUGE3TYI2KY/5F51FE0A-D57A-42A1-B64E-4F6AA9B726A9.JPG Berwyn Pergola After cutting out the pieces, I had a nice set of templates to use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383511490-PVLJKQG98B4FXNO77F2L/IMG_7922.JPG Berwyn Pergola After gluing up some boards for the larger outer posts (not shown here), I put together the smaller inner arches to create the central panel. The spacer blocks were used to keep things in place while I laid out for a radial lattice that was part of the design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383463303-YPW2SAEKF3QQM5OJSVPN/C99D9ACC-F9DC-4040-89C3-4C9920CB13CB.JPG Berwyn Pergola Here you can see the radial lattice of the central panel. All the joints were half-lapped and glued for extra strength. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383482679-9VW6GNTKIQO04SA7Z5QQ/IMG_7740.JPG Berwyn Pergola Next up I got to work on fabricating the large outer arch. Multiple layers of cedar were used to create this arch, along with a lot of waterproof wood glue. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383455076-X5GLDOU64TBUVMCZUZHX/04B806BE-89E0-4354-B73D-6E429D2C44D3.JPG Berwyn Pergola Part of the job included turning a pair of custom finials on the lathe to match ones that were on the home. I don't get a lot of call for lathe work, so it’s a fun change of pace. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383518041-IVQOOLY0PF3JLQ1JOKP3/IMG_7988+2.JPG Berwyn Pergola After fabricating the other parts and painting everything, I hauled it to the site and laid it out for final assembly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383528611-6CVQZEBMJWJ2HS7DE3ON/IMG_7990+2.JPG Berwyn Pergola A few extra hands from Doyle & McDonnell, Inc made all the difference in getting the pergola into its final position. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383534754-HTI29OIAPVNTIMVR8FUS/IMG_8997+2.jpg Berwyn Pergola After the pergola was installed and secured to the wall, I did a few final touchups. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383457275-P33GUR6YBVPJ9WKAMRQA/01950F92-6E12-4D37-8F3C-CF874AF3BA32+2.JPG Berwyn Pergola The finished project. Design by Hess Landscape Architects, and landscaping by Doyle & McDonnell, Inc. http://www.greengatewoodworks.com/our-mudroom-lockers daily 0.75 2019-12-16 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508332921-4IOL6VACYSL0PFU10OGX/IMG_8530.JPG Our Mudroom Lockers My mudroom was lacking proper storage for coats, book bags, etc, so I decided to make a set of lockers for my wife, myself, and my two daughters. I had installed a reclaimed brick floor in that room a few years prior, so when I built the lower case for the lockers I had to scribe it to fit the fairly uneven surface of the bricks. Here, you can see the lower locker case upside down after the wavy scribe cuts had been made. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508332921-4IOL6VACYSL0PFU10OGX/IMG_8530.JPG Our Mudroom Lockers My mudroom was lacking proper storage for coats, book bags, etc, so I decided to make a set of lockers for my wife, myself, and my two daughters. I had installed a reclaimed brick floor in that room a few years prior, so when I built the lower case for the lockers I had to scribe it to fit the fairly uneven surface of the bricks. Here, you can see the lower locker case upside down after the wavy scribe cuts had been made. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508333193-6HC4N8PA65FFWDKK0H04/IMG_8532.JPG Our Mudroom Lockers Here you can see how the scribe cuts fit in with the surface of the bricks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508338395-WRP6XVECX840BOD18OXP/IMG_8535.JPG Our Mudroom Lockers A wider shot of the installed lower case. The hooks in the background (and another row up higher out of view) are what we had used prior to this for hanging coats, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508341162-E8UY78EV9K5PBTC6X0UJ/IMG_8547.JPG Our Mudroom Lockers Next up was milling some black walnut planks to make a bench top. After I had them roughly planed to size, I played around with which sides to join up until I was happy with the look. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508327843-ASGC2C3X9F9PAMO5H3GL/377DB8F8-17FD-4F31-AA63-23042F998CC1+2.JPG Our Mudroom Lockers This is the finished top after it had been fit to the space, sanded, and then coated with a satin polyurethane. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508346426-UZ4Q5GGY1R4RUR1RA55S/IMG_8590.JPG Our Mudroom Lockers Next up was installing the upper units. After this it was on to face frames, end panels, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508328395-5NR59M611MJP488HC8Y7/E1A84AC7-EA57-48EE-ABCB-A5FEEB979240.JPG Our Mudroom Lockers Here my helpers are keeping a close eye on me and asking a million questions while I touch up the final coat of paint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508405620-MTMX25UD1WPM04NSULVN/D4EDB04D-BF60-43B1-A35B-942930102A64.JPG Our Mudroom Lockers I designed the upper area of our lockers to have a smaller cubby section for storing smaller items, hats, gloves, etc. My wife and I were unable to find baskets we liked for the space, so I created this apple crates from some reclaimed pine I had in the shop. Each one also got a clear plexiglass insert on the bottom to keep anything from falling through the cracks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508322317-DWQV5WOPFJ0UH8N0KPBB/69BF6401-8481-4FF6-9E24-30CB4D9FE09C.JPG Our Mudroom Lockers A finished shot of the completed project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508323506-JBQSBTVD4GN8AHEN3WNG/0443C519-3F93-432E-BED0-921919A6494B.JPG Our Mudroom Lockers Each locker also got an authentic locker number courtesy of my father-in-law who worked for Penco Products. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508324772-6IBP5JAQ7BO3W0E7OOF0/45083128-774E-463D-8FBD-3DA0D7F07182.JPG Our Mudroom Lockers While I was putting in the lockers, I also finished up this taller shelving unit I had made previously for the other side of the room. Using a cutoff from the locker bench top, I put in a matching black walnut seat over our radiator. http://www.greengatewoodworks.com/black-walnut-serving-boards-1 daily 0.75 2020-01-31 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580503357480-I5E3WYJBKBDFNZT321YR/77D23A44-2831-4FA4-896D-E2E9C0307973.JPG Black Walnut Serving Boards This trio of black walnut serving boards were made as Christmas presents in 2019. Each board was 18” long by 13” wide by 1-1/8” thick with a large hole that fits an oven-proof Le Creuset mini round cocotte. The post can be used to hold dips, etc. and rest on their handles, so they don’t scorch the tabletop below if they’re hot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580503357480-I5E3WYJBKBDFNZT321YR/77D23A44-2831-4FA4-896D-E2E9C0307973.JPG Black Walnut Serving Boards This trio of black walnut serving boards were made as Christmas presents in 2019. Each board was 18” long by 13” wide by 1-1/8” thick with a large hole that fits an oven-proof Le Creuset mini round cocotte. The post can be used to hold dips, etc. and rest on their handles, so they don’t scorch the tabletop below if they’re hot. http://www.greengatewoodworks.com/craftsman-style-china-cabinet daily 0.75 2020-01-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179142795-5CX0THIDNUACTC20BGHW/IMG_9829.jpg Craftsman Style China Cabinet An old friend of mine had picked up a pair of antique doors and asked me to use them to create a piece of furniture for her. Since it was going to her home in Syracuse, New York, it seemed only fitting that we go with the Craftsman style popularized by Gustav Stickley in Syracuse in the early 20th Century. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179142795-5CX0THIDNUACTC20BGHW/IMG_9829.jpg Craftsman Style China Cabinet An old friend of mine had picked up a pair of antique doors and asked me to use them to create a piece of furniture for her. Since it was going to her home in Syracuse, New York, it seemed only fitting that we go with the Craftsman style popularized by Gustav Stickley in Syracuse in the early 20th Century. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179142856-0U1Z3FXZ2HZB8FZ986MI/IMG_9830.jpg Craftsman Style China Cabinet This piece is based on and inspired by Stickley’s #815 china cabinet. It has solid quarter-sawn white oak in the frame, with flat-sawn white oak panels for contrast. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179143897-1GUXR1LZOLRWRLY6RAMM/IMG_9831.jpg Craftsman Style China Cabinet Inside the cabinet are three adjustable shelves, also fabricated from quarter-sawn white oak. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179143894-89AI1J3TCQY17DQSKM2K/IMG_9832.jpg Craftsman Style China Cabinet I opted to go with a sawtooth adjustable shelf system to maintain the antique character of the piece. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179144724-VKTX4S7C82R9P3P1PW43/IMG_9833.jpg Craftsman Style China Cabinet The door latch and catch hardware were original to the doors and were refinished for this project. http://www.greengatewoodworks.com/reclaimed-red-oak-coffee-table daily 0.75 2020-01-25 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579953692366-QGNJ5WSJZTCVCV0P15VQ/IMG_9168.JPG Reclaimed Red Oak Coffee Table A client approached me to create a coffee table for his girlfriend as a surprise present. I milled up pieces from some of the reclaimed red oak barn beams I had in stock at my shop, and then assembled the base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579953692366-QGNJ5WSJZTCVCV0P15VQ/IMG_9168.JPG Reclaimed Red Oak Coffee Table A client approached me to create a coffee table for his girlfriend as a surprise present. I milled up pieces from some of the reclaimed red oak barn beams I had in stock at my shop, and then assembled the base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579953733692-A2ECH78VUXYI8I1T6X03/IMG_9805.JPG Reclaimed Red Oak Coffee Table The finished table in it’s final home. The top is a piece of marble that has been passed down through the client’s girlfriend’s family for generations, and it pairs perfectly with the barn wood. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579953737468-856R51IRJXRQ2BHE0RGT/IMG_9807.JPG Reclaimed Red Oak Coffee Table The barn beams this wood came from were 100-200 years old. Holes from the original draw-bore joints are visible in the piece as well as staining from the original iron cut nails. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579953731560-BGNMS5SYMCGGYL2UTF1Y/IMG_9804.JPG Reclaimed Red Oak Coffee Table One more finish picture with Mabel the cat. http://www.greengatewoodworks.com/reclaimed-barn-beam-mantle daily 0.75 2020-01-25 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579952397279-B2AN5O8OUNN06V53JH32/IMG_9200.JPG Reclaimed Barn Beam Mantle A client commissioned me to create a new mantle for their living room from one of the antique reclaimed red oak barn beams I had in stock at my shop. I cut it to length using a handsaw to create a historically accurate look for the end of the beam. Then I got to work hollowing out the back of the beam to reduce the overall weight of the mantle so it would work with the existing mounting hardware the client had in place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579952397279-B2AN5O8OUNN06V53JH32/IMG_9200.JPG Reclaimed Barn Beam Mantle A client commissioned me to create a new mantle for their living room from one of the antique reclaimed red oak barn beams I had in stock at my shop. I cut it to length using a handsaw to create a historically accurate look for the end of the beam. Then I got to work hollowing out the back of the beam to reduce the overall weight of the mantle so it would work with the existing mounting hardware the client had in place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579951738659-UGXDEI5CR7XSUB6B0YTM/IMG_9198.JPG Reclaimed Barn Beam Mantle https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579951742524-ZUFG2VTCA7LGWQQLFIQC/IMG_9486.JPG Reclaimed Barn Beam Mantle After lightly sanding the beam and finishing it with a satin polyurethane, I test fit the beam in place. It has original mortise and tenon joinery still intact, as well as cut marks on the face from when it was hand-hewn 100 to 200 years ago. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579951772598-8GBVSCQY9JIGZ6YOWJM4/A2FA6D0C-1C49-4ECC-9727-ED00DBBFDE48.JPG Reclaimed Barn Beam Mantle A picture the client sent to me of the finished mantle decorated for Christmas. http://www.greengatewoodworks.com/philadelphia-builtins daily 0.75 2020-02-11 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386035578-NSQYTZ27Q61G7TAKQHBC/FA4C0FBD-B28D-4EF8-9B24-3E086F890CCC.JPG Philadelphia Built-ins A client contracted me to create built-ins on either side of their existing fireplace. This is the before picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386035578-NSQYTZ27Q61G7TAKQHBC/FA4C0FBD-B28D-4EF8-9B24-3E086F890CCC.JPG Philadelphia Built-ins A client contracted me to create built-ins on either side of their existing fireplace. This is the before picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386051498-6T2A9XH4SJ68I5IRIR5L/IMG_9849.JPG Philadelphia Built-ins The client chose to have two live-edge white oak countertops installed for this project. This is the left side countertop during fitting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386051546-MXCVYHBXDPSQYQV6FY7O/IMG_9880.JPG Philadelphia Built-ins Setting the upper units. Next up was installing LED lights behind the shelves and fitting column details. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386060309-XPNGUQ4G5W22WVUSFX4X/IMG_9908.JPG Philadelphia Built-ins The columns were scribed to fit exactly against the existing fireplace stone. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386039718-L4QXOPQF0VK7T7DKXYYM/5063F26D-2B4F-4AC8-B1A1-7051A77E6767.JPG Philadelphia Built-ins The finished project. The LED lights cast a soft light into the room, while the cabinets provide additional storage and visual depth for the room. http://www.greengatewoodworks.com/giraffe-bookshelf daily 0.75 2020-03-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1583708953359-EOCYELG9NM9LPUWKOUZI/E1C19A92-3621-431E-BBA4-75FCF6A788B5.JPG Giraffe Bookshelf This was a set of giraffe and tree bookshelves I made as part of a fundraiser for my daughter’s nursery school. The pair of bookshelves fit together to show a hungry giraffe nibbling on a tree. For smaller spaces, the bookshelves can be displayed apart. The design is also reversible, allowing for even more options. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1583708953359-EOCYELG9NM9LPUWKOUZI/E1C19A92-3621-431E-BBA4-75FCF6A788B5.JPG Giraffe Bookshelf This was a set of giraffe and tree bookshelves I made as part of a fundraiser for my daughter’s nursery school. The pair of bookshelves fit together to show a hungry giraffe nibbling on a tree. For smaller spaces, the bookshelves can be displayed apart. The design is also reversible, allowing for even more options. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1583708953307-WDWEP2H2XSV58HX69ZYJ/C9A2E89C-933C-4CF1-AAA9-D8BB8DB0FAE2.JPG Giraffe Bookshelf The giraffe is painted in a cheery bright yellow and has brown accents on its hooves, mane, tail, and ossicones. http://www.greengatewoodworks.com/penn-valley-hutch daily 0.75 2020-07-30 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621437365-1SELQBMXZJGIZUVF8SQY/IMG_0865.JPG Penn Valley Hutch I created this built-in hutch for a client who wanted to replace an existing kitchen desk in order to gain more usable storage space. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621437365-1SELQBMXZJGIZUVF8SQY/IMG_0865.JPG Penn Valley Hutch I created this built-in hutch for a client who wanted to replace an existing kitchen desk in order to gain more usable storage space. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621445068-MZVIWF2CKMZRAJ1XOCT3/IMG_0869.JPG Penn Valley Hutch I built this hutch for a client who wanted to replace an existing kitchen desk in order to gain more usable storage space. https://static1.squarespace.com/static/577c5a6715d5db726ef510c0/5ede369741190d45421f5db9/5ede3706181ec82b51da2fdf/1591621382842/ Penn Valley Hutch https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621437783-IB3KHAM7C428G9S9BPQ4/IMG_0866.JPG Penn Valley Hutch The lower cabinet has two standard drawers and four pull-out shelves. The upper cabinet sits atop a solid black walnut countertop and has several shelves for additional storage and spice racks attached to each door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621442853-CV6I93X82IHUDIA6MH2V/IMG_0868.JPG Penn Valley Hutch The spice racks are made primarily from maple with 3/8” dowels in front of each shelf. The four upper shelves are designed to hold small spice jars, while the three lower shelves are set up to accommodate larger ones. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621684496-YUSO44WP0PXS90Y8BGCT/IMG_0872.JPG Penn Valley Hutch In addition to the cabinet, I also built this charging station as part of the project. The rear area is for sorting mail, while the front slots hold phones and tablets for charging. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621684975-IMY9SL096ABL9ANK7LGP/IMG_0873.JPG Penn Valley Hutch The upper charging area opens up to access a hidden power strip concealed in the back. All charging cables can be plugged into this strip, which is then plugged into a standard wall outlet. http://www.greengatewoodworks.com/media-peninsula daily 0.75 2020-07-30 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133794547-I9FK1GE9N6BQ215XBN00/IMG_1179+2.JPG Media Peninsula A client asked me to make them a peninsula for their kitchen, with a wooden top made from some of the reclaimed barn beams I had in stock at my shop. The countertop is 3” thick, and approximately 48” wide by 60” long. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133794547-I9FK1GE9N6BQ215XBN00/IMG_1179+2.JPG Media Peninsula A client asked me to make them a peninsula for their kitchen, with a wooden top made from some of the reclaimed barn beams I had in stock at my shop. The countertop is 3” thick, and approximately 48” wide by 60” long. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133817418-B6ALVOPY6X5JPF315KW1/IMG_1184+2.JPG Media Peninsula The barn wood is around 100-200 years old and has a lot of character. In order to maintain that character, I recommend to my clients that we only clear coat the wood, instead of staining it. Here I was using a quick application of mineral spirits to check the color of the final piece once a clear coat was applied. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133831719-JVG0VW1ML2OTL2J7IH3G/IMG_1392.JPG Media Peninsula This countertop was extremely heavy, and since I work alone I had to come up with a way to safely move it into the house. Using some pneumatic wagon wheels I had leftover from another project, I put together some quick dollies to make my life a little easier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133843493-45CZVJB8S9O9MFN2YXIN/IMG_1414.JPG Media Peninsula The peninsula installed. The base cabinet is painted a satin black and has bookshelves on one end for cookbooks, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133838393-UVNSXDGIS8HN1L7MOLCC/IMG_1408.JPG Media Peninsula The main cabinet area has double doors on each side that open for easy access to the interior storage area. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133844530-6UEA4X2XS4SAWGDZSISW/IMG_1447.JPG Media Peninsula The finished top overhangs each side to allow for seating along each of the long sides. http://www.greengatewoodworks.com/squirrel-mailbox daily 0.75 2020-07-30 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596132572891-99R8COS4QNHCTIO6901Q/IMG_0567.JPG Squirrel Mailbox My cousin had bought a tiny picnic table to act as a squirrel feeding area to entertain her grandson, and she mentioned also needing a mailbox, so I put this together for her one afternoon. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596132572891-99R8COS4QNHCTIO6901Q/IMG_0567.JPG Squirrel Mailbox My cousin had bought a tiny picnic table to act as a squirrel feeding area to entertain her grandson, and she mentioned also needing a mailbox, so I put this together for her one afternoon. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596132563397-MC4Z2J47O9GVKGGWR4GI/3539CE3A-6D9B-4CD1-875C-83157E3F6039.JPG Squirrel Mailbox The mailbox is made from black walnut, with maple for the post and base. The small functional flag is made from a thin piece of plywood. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596132566697-JD6F2F8DDQEKX86IMDS2/IMG_0564.JPG Squirrel Mailbox The door opens on a small hinge concealed below, and the inside of the mailbox is hollow to allow for small notes, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596132563414-01ZHMFWO69MP1PVK8VGG/8733348D-5014-46C9-8C79-5BA8395D6F9F.JPG Squirrel Mailbox Luckily we had this squirrel finger-puppet on hand for the photoshoot. http://www.greengatewoodworks.com/king-of-prussia-entertainment-center daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606157775904-RVF6MJL5CK5AHKKCRPE3/056BA51A-B658-4E28-9BEC-BDE6CFA28C87.JPG King of Prussia Entertainment Center I didn't get many pictures along the way with this project, but it was an interesting one. The clients wanted to have an entertainment center along this wall of their living room, but the design was constrained by the long horizontal window high up on the wall. They wanted to include their TV in the design, but with an option to keep it hidden when not in use which lead us to the following solution… https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606157775904-RVF6MJL5CK5AHKKCRPE3/056BA51A-B658-4E28-9BEC-BDE6CFA28C87.JPG King of Prussia Entertainment Center I didn't get many pictures along the way with this project, but it was an interesting one. The clients wanted to have an entertainment center along this wall of their living room, but the design was constrained by the long horizontal window high up on the wall. They wanted to include their TV in the design, but with an option to keep it hidden when not in use which lead us to the following solution… https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606157775908-69QVKWVD2WK68KW0UTDB/402BBCFD-CC19-4496-A3CA-445740853D73+2.JPG King of Prussia Entertainment Center In lieu of standard barn doors I came up with an idea for shallow sliding shelf cases as you can see in the picture above. Mounted on mini-barn door tracks, the cabinets glide open to reveal the TV within. They sit just above the countertop and have additional plastic pulley wheels, normally used in 3D printers, mounted along the back to keep them aligned properly and also to keep them from scuffing the main cabinets behind them. http://www.greengatewoodworks.com/my-greenhouse daily 0.75 2020-11-24 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185083276-2ABP7ETEWMEMEIA77C5U/IMG_0812.jpg My Greenhouse When I had L.S. Stone Masonry at my house applying the exterior stone, I also had them add it to the back of the chimney that sits inside our greenhouse room. My wife and I knew we wanted to have a flat panel wainscot wall along the bottom, so I installed a stained maple top rail to give the mason’s a stopping point for their stone. Once they had completed their work I was able to get started putting in the final floors and doing the trim work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185083276-2ABP7ETEWMEMEIA77C5U/IMG_0812.jpg My Greenhouse When I had L.S. Stone Masonry at my house applying the exterior stone, I also had them add it to the back of the chimney that sits inside our greenhouse room. My wife and I knew we wanted to have a flat panel wainscot wall along the bottom, so I installed a stained maple top rail to give the mason’s a stopping point for their stone. Once they had completed their work I was able to get started putting in the final floors and doing the trim work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185094749-GOGLG28IP6OJ3AHLJJCH/IMG_1130.jpg My Greenhouse Our greenhouse room, along with our mudroom and laundry room, used to be where our porch was before we renovated. We decided we wanted to keep the “porch” feel in those rooms, so we designed them with tongue-and groove board ceilings and brick floors. I had already completed the floors in the mudroom and laundry room, and now it was time to install the greenhouse floors. Using the reclaimed bricks I had collected a few years earlier, I laid the amount I needed out in our driveway so I could clean them off and then pick and choose them as I worked. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185088226-NHDZRPS18E294SYBL0J9/IMG_1129.jpg My Greenhouse After installing the cement backer board, I got to work installing the bricks in a basket weave pattern. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185365319-N4HFFNFQHUFQ3YP2PCFN/IMG_1141.jpg My Greenhouse My wife wanted to help so I taught her how to lay brick. Turns out she’s a pretty decent mason. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185114334-M0ZSQCDA0UNZP0YHUKNZ/IMG_1288.jpg My Greenhouse After the bricks were installed, I sealed them, then pointed them, and then sealed the entire floor again. Sealing the bricks before pointing them allowed me to grout the joints similar to a ceramic tile floor, and it kept the normally porous bricks from getting stained from the mortar. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185115453-XDXG19YDM011UN1CQBTX/IMG_1478.jpg My Greenhouse After the floor was finished I framed up the wall and roughed in the electrical lines for new outlets. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185120166-CQ61K2N0O2SBERM4MK9O/IMG_1527.jpg My Greenhouse Next, I closed up the wall and then trimmed everything out including adding baseboards and window trim to the remainder of the room. . https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185078946-X2B21IB6MQBJ1I6EK5SH/C592B8E8-5EEB-4629-A57D-82D75FB72CCC.JPG My Greenhouse The finished product. http://www.greengatewoodworks.com/halloween-coffin daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606166342768-9QGXMJDKEBI0T6EXX0NV/62326222702__B326FD00-08E6-4A2C-B2DE-DE64BAFEBE9A.JPG Halloween Coffin https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606166342768-9QGXMJDKEBI0T6EXX0NV/62326222702__B326FD00-08E6-4A2C-B2DE-DE64BAFEBE9A.JPG Halloween Coffin https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606166346675-012IHOL2X89X8DV5OJ5D/IMG_2264.jpg Halloween Coffin This is an animatronic coffin for a client as a Halloween decoration. Here you can see the basic case and the internal pneumatic piston that opens and closes the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606166346156-HUO3XUJQMCXKIY7KAW85/IMG_2687.jpg Halloween Coffin This is the brains of the unit, hidden in a recessed area in the back of the coffin. It is controlled by an Arduino R3 microcontroller and triggered by a passive infrared motion sensor. When the infrared sensor picks up motion, it sends a signal to the Arduino which trips a solenoid that allows air to flow into one end of the piston, opening the door. After a few moments the solenoid trips back to it’s original position and air is pushed into the piston from the opposing end, closing the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606166865711-8F59JR4V9RFB5K6NTZHD/image-asset.jpeg Halloween Coffin Here my daughters test it out for me. The sensor, hidden in the small black box on a post just above the pumpkin, picks up motion from around 20-25’ away. This was a fun project that allowed me to test my hand at basic programming and robotics which is something I’ve been wanting try for a while. Hopefully I’ll be able to introduce animatronic features into some of my other projects in the future. http://www.greengatewoodworks.com/downingtown-builtins daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159093022-I7Z2E3YD6O31JK64JNPL/7A6EE550-B5AF-4C94-9D83-C291AD8EF1A7.JPG Downingtown Built-ins For this project the clients wanted to add built-ins on either side of their fireplace to give them additional storage and shelf space for a large collection of books. The existing mantle was red oak, and the clients were interested in having new countertops made for their built-ins from the reclaimed red-oak barn beams I had in stock at my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159093022-I7Z2E3YD6O31JK64JNPL/7A6EE550-B5AF-4C94-9D83-C291AD8EF1A7.JPG Downingtown Built-ins For this project the clients wanted to add built-ins on either side of their fireplace to give them additional storage and shelf space for a large collection of books. The existing mantle was red oak, and the clients were interested in having new countertops made for their built-ins from the reclaimed red-oak barn beams I had in stock at my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159172419-86KP69Y034F2UZ5S6AQ3/IMG_1744.jpg Downingtown Built-ins I began by milling several of the beams I had at my shop and then arranging the boards for the new countertops. The clients wanted to highlight the mortise pockets in the wood from the original beams, so I tried several different arrangements of the boards to both highlight these features and to get the best flow of color across the countertop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159126980-LLC4Z88QXEZOPGPFAO9Y/IMG_2176.jpg Downingtown Built-ins Here the lower cabinets and countertops have been fit and installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159131356-RCLWEQ9FCK2IZVWLRT34/IMG_2177.jpg Downingtown Built-ins Fitting the upper cabinets was done very carefully to align with the cabinets below as well as fit to the existing fireplace stonework. The mantle was cut down to line up with the sides of the new upper cabinets exactly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159093000-G33ZECCH0ZM8R0ACETN0/26FC5EA4-B635-4327-A587-FC3C42EF83A5.JPG Downingtown Built-ins The finished product. In addition to the built-ins, I also sanded, stained, and finished the existing mantle to match the color of the new countertops. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159271809-2D1Z64NRXAUJZA0EAW3N/055C8316-111F-487B-9391-DF38C83CF7FB+2.JPG Downingtown Built-ins A close-up shot of one of the countertops to how the mortise pockets were incorporated into the design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159094413-XNU7JVZU7XVJJUJC41FC/3431D5A1-CE8D-46D1-A20C-67735D1BD07C+2.JPG Downingtown Built-ins The pulls for the cabinet doors were made from old spigot handles the client had salvaged from their family farm. I added new hardware and custom spacers to make them function like standard cabinet handles. http://www.greengatewoodworks.com/plymouth-meeting-banquette daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160271198-8J00NRWSI1H2OVVJVCD8/image0.jpeg Plymouth Meeting Banquette https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160271198-8J00NRWSI1H2OVVJVCD8/image0.jpeg Plymouth Meeting Banquette https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160275886-0OYBIL1GI538JLWM6KHY/image1.jpeg Plymouth Meeting Banquette On this project the client wanted to create a breakfast nook with built-in bench seating. We discussed a few different options and ultimately chose an open-bottom, flat-panel banquette design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160275031-KKLV8T0GB9K7WL5YH53P/IMG_3156.jpg Plymouth Meeting Banquette Here the lower section is installed. Arched struts as well as steel reinforcement under the bench allow for the completely open base with no visible support https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160277749-ZFSS7ZMJDD2XFMUJUR1E/IMG_3160.jpg Plymouth Meeting Banquette The upper section of the bench is angled back slightly for comfort. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160279152-DBH02VHJ0UZJQTRKKN60/IMG_3230.JPG Plymouth Meeting Banquette The finished product, trimmed out to create the flat-panel design. Custom-made cushions will complete this new seating area. http://www.greengatewoodworks.com/ardmore-door daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148344093-0EH4K9OYYL12KZ20GZP9/DA5AF746-CA16-4C30-AA07-72F7FE701884.JPG Ardmore Door A client contacted me to replace the arched entry door on their Tudor home. Besides just replacing the door, the client also wanted to add a lot more glass to the door to help brighten their foyer. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148344093-0EH4K9OYYL12KZ20GZP9/DA5AF746-CA16-4C30-AA07-72F7FE701884.JPG Ardmore Door A client contacted me to replace the arched entry door on their Tudor home. Besides just replacing the door, the client also wanted to add a lot more glass to the door to help brighten their foyer. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148971114-LYNNJPKXOD7XHAV4M1O1/IMG_1620.jpg Ardmore Door First step for me was making a template and laying out how all the new sections would go together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148348733-69TJ4GGUTGVVB355YKVP/IMG_1624.jpg Ardmore Door Once I had laid out for all the parts, I made up secondary smaller templates for each section. These are then tacked to the white oak lumber I milled for the door and a router is used to get each piece to its final shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148348933-SI1CP895IS06VHEMRQOZ/IMG_1628.jpg Ardmore Door A quick test-fit to make sure everything comes together nicely before I attempt gluing it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148323818-VR9OJE329BCHV5XYJ3F6/61728974811__B0CA31E4-E1CC-4712-98D1-E4A1FFC1BF62.JPG Ardmore Door https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148352704-7MYUXSVG0W3SIL5VVPMA/IMG_1637.jpg Ardmore Door For the actual gluing-up of the door frame, I made up some plywood torsion boxes cut to fit the top arch. This allows me to clamp things together without worrying about the clamps sliding off the arched sections. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148357375-TMETV8HL4IKQ1Z995YWN/IMG_1643.jpg Ardmore Door After the glue had dried, I removed the clamps and put the original template overtop of the door to make sure had lined up properly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148357101-HISD0ZTIX8FZ33D6A1EJ/IMG_1660.jpg Ardmore Door This door was a true divided-lite door, so here I am installing the center framework for the windows. The lower floating panel has already been painted the final color. Doing this ensures the panel never reveals any unpainted areas as it grows and shrinks with the change of seasons. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148361396-VNJ07OXMIB2CVKQ2AGSV/IMG_1673.jpg Ardmore Door Inside each section I installed smaller T-shaped pieces that will hold the window panes slightly apart. Also at this stage I used epoxy to fill any minor cracks or natural defects in the wood. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148361471-E2PUTTPMD68W3Z1XOUB4/IMG_1674.jpg Ardmore Door Several coats of oil-based primer prepare the door for the final paint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148364319-8AHRYI60VYQZIPP1HQ7D/IMG_1688.jpg Ardmore Door Before installing the window panes I painted the entire door the final color to make sure there would be no unpainted spots showing through between the panes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148364963-X3JDZDKMQNTV0CIXHHC5/IMG_1729.jpg Ardmore Door Next up was installing the window panes and small retainer strips that hold them all in place. For this project I used 3/8” thick plexiglass panels because of the need for custom cutting the top angled panes. Plexiglass can be cut with standard woodworking tools, whereas glass can require more specialized tools and techniques. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148368934-9NGSUIEL2CW768CEFFUW/IMG_1902.jpg Ardmore Door I picked up a pair of these door dollies for the project. They allow you to stand the door upright and adjust it in all directions to aid in installation. They also make it a breeze to move a heavy door like this for transport. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148342802-JJCW920GQ7U1J4LXIW9R/A673019F-D737-4D2C-96D0-BC32E7CD9EBE.JPG Ardmore Door The finished product, installed and fit to the existing doorway of the home. http://www.greengatewoodworks.com/bottle-cap-table daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606168022883-3H9SUCB60E0T6AWJD1T0/62094950819__16FE8DDF-1A9E-4504-85CA-4643E63DE802.JPG Bottle Cap Table During the summer of 2020 I was laid up from foot surgery and couldn’t work. There’s only so much sitting around I can do, so I decided to work on this project for my house. My wife had found a tall cafe table to put near our pool table, and we decided to give it a bottle-cap top. My first step was to router out the original top of the table to the proper depth, then sand it down and paint it black. After that, I began installing caps in a hexagonal pattern, working outwards from the center, securing each cap in place with clear silicone caulk. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606168022883-3H9SUCB60E0T6AWJD1T0/62094950819__16FE8DDF-1A9E-4504-85CA-4643E63DE802.JPG Bottle Cap Table During the summer of 2020 I was laid up from foot surgery and couldn’t work. There’s only so much sitting around I can do, so I decided to work on this project for my house. My wife had found a tall cafe table to put near our pool table, and we decided to give it a bottle-cap top. My first step was to router out the original top of the table to the proper depth, then sand it down and paint it black. After that, I began installing caps in a hexagonal pattern, working outwards from the center, securing each cap in place with clear silicone caulk. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606168029908-FOLJF14L1LBARUBLRP33/IMG_2123.jpg Bottle Cap Table After I had installed all the caps, I covered them all with an epoxy pour. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606168026803-8QV7WVLFAFAGBNEV3799/IMG_2087.jpg Bottle Cap Table A close up of the caps https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606168030445-DV2EB39BG2BC3MBCNN4S/IMG_2148.jpg Bottle Cap Table Here is the finished product. After the epoxy had fully cured, I sanded out any imperfections, restained and sealed the wood edge, and then polished and buffed the top to a gloss finish. http://www.greengatewoodworks.com/malvern-office-renovation daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161125999-G6QL8D5LT90PRYX5B1MH/IMG_3220.jpg Malvern Office Renovation This project came to me from two clients who were looking to maximize the use they could get out of their existing home office. The original setup shown here only allowed for one person to work in the room. They had in mind a large T-shaped desk which would allow them to both utilize the space, so I sketched up a design and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161125999-G6QL8D5LT90PRYX5B1MH/IMG_3220.jpg Malvern Office Renovation This project came to me from two clients who were looking to maximize the use they could get out of their existing home office. The original setup shown here only allowed for one person to work in the room. They had in mind a large T-shaped desk which would allow them to both utilize the space, so I sketched up a design and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161121561-8DSGO42FALHT71NK65N1/IMG_2773.jpg Malvern Office Renovation The design called for floating shelves above the desk with built-in lights, and three lower cabinets at the ends of the desktop to allow for maximum leg-room underneath. Here you can see the lower cabinets on the far right and (somewhat obscured by my tools) on the left. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161116386-B3UKB5ND07MX6TA55TTM/IMG_2472.jpg Malvern Office Renovation I designed the desktop to be made of three large sections of black walnut. Here you can see me gluing up one of those three sections. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161121272-9W0DH61C58EP0QV6A204/IMG_2786.jpg Malvern Office Renovation Once I had the desktop sections shaped and dry-fit in my shop, it was time to install them. The first two sections would go along the wall, with the third coming in at a 90 degree angle to create the T-shaped desktop. In order to install it safely by myself, I made up an angled support to hold the two rear sections in place while I joined them on site. Then I lowered that support and eventually slid it out, allowing the partial desktop to settle into place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161126195-18T06H5501TP2GH1UHAK/IMG_2793.jpg Malvern Office Renovation Here the third section of the desktop as well as the third lower cabinet are in place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161123172-1YVQ0AWFGC3S660HBE7K/IMG_3217.jpg Malvern Office Renovation The completed desk. The lower cabinets were painted in a dark blue color which offset the color of the black walnut top nicely. Each lower cabinet has one drawer and a door for storage underneath, and the outer lower cabinet has drawers on either end and the storage space below is accessible from both ends. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161124691-QB6CRGBMXUIUH9B6AT5E/IMG_3218.jpg Malvern Office Renovation A closer shot showing the finished black walnut desktop and how the three sections come together. Custom slots were cut near the rear wall to allow for installation of the client’s monitor brackets. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161093841-SNDEOE9HPIBX0M02S19I/IMG_3219.jpg Malvern Office Renovation Underneath the desk are two tapered legs made from solid maple. These support the desktop above as well as the embedded steel reinforcements that are used to strengthen the desktop. The floating shelves along the rear wall provide a place for components to be stored, and the panels along the rear wall are removable to allow cables, etc to be concealed. http://www.greengatewoodworks.com/chester-springs-pantry-conversion daily 0.75 2020-12-04 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1607111997221-TZJBAZD05TKM9DXL20I1/IMG_6735.jpg Chester Springs Pantry Conversion This room was originally a powder room, but the client wanted to change it to a walk-in pantry instead. After other contractors were done removing some of the original plumbing and installing the new tile floor, I came in to start on my work. Here you can see the cabinets set and wiring roughed in for some under shelf lighting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1607111997221-TZJBAZD05TKM9DXL20I1/IMG_6735.jpg Chester Springs Pantry Conversion This room was originally a powder room, but the client wanted to change it to a walk-in pantry instead. After other contractors were done removing some of the original plumbing and installing the new tile floor, I came in to start on my work. Here you can see the cabinets set and wiring roughed in for some under shelf lighting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1607111996493-3O3WO9I3X4CP882MUHO6/IMG_6928.jpg Chester Springs Pantry Conversion Here the counters have been installed, along with floating shelves on the left side. There is a single overhead light fixture in this room, but the client wanted to add in some additional lights, so I installed LED lights under and above the cabinet, as well as underneath the floating shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1607111998287-KFNRMNEX9QD34KQEBEP9/IMG_6966.jpg Chester Springs Pantry Conversion A closer shot of the under-shelf lighting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1607111886211-MNQFY0HONTHTLNBJZIG3/IMG_3129.jpg Chester Springs Pantry Conversion The finished product. The counters and floating shelves are solid black walnut, there are pull-out shelves on the lower left cabinets, a pull-out trash can under the sink, and a wine fridge on the lower right. http://www.greengatewoodworks.com/my-kids-builtins daily 0.75 2021-05-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621282972912-9N2P381MOAB4K5DWUA7T/1217+girls+bulit-ins3.JPG My Kids' Built-ins My daughters share a room and needed some extra storage, shelving, etc, and we wanted to incorporate a window seat as well. Since it was for my own house, I didn’t take pictures except for these finished ones. The radiator cover on the lower right is held in place with magnets and easily removed when needed, and the bench seat lid opens up for trunk storage inside. I created lifted baseboards on this project to give it more of a “furniture” feel, and the entire project is up on 3/4” spacers to allow for installation of hardwood flooring in the future. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621282972912-9N2P381MOAB4K5DWUA7T/1217+girls+bulit-ins3.JPG My Kids' Built-ins My daughters share a room and needed some extra storage, shelving, etc, and we wanted to incorporate a window seat as well. Since it was for my own house, I didn’t take pictures except for these finished ones. The radiator cover on the lower right is held in place with magnets and easily removed when needed, and the bench seat lid opens up for trunk storage inside. I created lifted baseboards on this project to give it more of a “furniture” feel, and the entire project is up on 3/4” spacers to allow for installation of hardwood flooring in the future. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621282976345-41XFNYGG14QL81R0NBNO/1217+girls+built-ins2.JPG My Kids' Built-ins I installed color-changing LED lights along the top of the built-ins. They are controlled by a switch inside the center bookshelf, and there are additional outlets and USB charging ports at that location as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621282988414-6QDAV48RELAF7QOM5YTG/IMG_4024.GIF My Kids' Built-ins The LED light color can be changed with a phone app or the included remote. They can be set to sync their color changes to music or ambient noise in the room and my girls have incorporated this feature into their nightly dance parties. http://www.greengatewoodworks.com/berwyn-builtin-bar-1 daily 0.75 2021-05-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281834268-45HEUVT0YZWZ4Q7GRBX7/D4D5C0E2-4FE6-4BAD-B617-BF18C959E49D.JPG Berwyn Built-in Bar A client asked me to create a built-in bar for this alcove in their basement. They had an existing wine fridge they wanted to incorporate into the design as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281834268-45HEUVT0YZWZ4Q7GRBX7/D4D5C0E2-4FE6-4BAD-B617-BF18C959E49D.JPG Berwyn Built-in Bar A client asked me to create a built-in bar for this alcove in their basement. They had an existing wine fridge they wanted to incorporate into the design as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281986894-24PMRBOGQHJKNDKENV5B/IMG_4933.jpg Berwyn Built-in Bar The black walnut countertop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281834553-OQDT0NTEYM6NOBBBJE4J/IMG_5120.jpg Berwyn Built-in Bar The finished project has inset flat panel doors, a black walnut countertop and shelf, and is painted in the Benjamin Moore color Hale Navy. http://www.greengatewoodworks.com/newtown-square-builtins daily 0.75 2021-05-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281143380-WWXT8ZQ6GZZVERZQEN2D/D936EDB7-94B4-42FB-B6BD-A19A5BBB6AEA.JPG Newtown Square Built-ins A client contacted me to create a set of built-ins flanking their existing fireplace. This was the space before I started. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281143380-WWXT8ZQ6GZZVERZQEN2D/D936EDB7-94B4-42FB-B6BD-A19A5BBB6AEA.JPG Newtown Square Built-ins A client contacted me to create a set of built-ins flanking their existing fireplace. This was the space before I started. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281142925-5V7BRGBSCGZZTYPU17U1/7F7D98FD-81A9-4408-A5B1-643F8E3F8490.JPG Newtown Square Built-ins The finished product has lower cabinets for storage, upper bookshelves, TV mounted over the fireplace and a new mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281143507-E7MCQNS7NZS33DXR5KOJ/EC571B96-8269-47DA-8201-FAB6B6B86AF3.JPG Newtown Square Built-ins LED lights, hidden under each shelf and controlled by a switch on the inner side of the left bookshelves, add ambient light to the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281142934-1L7U9OMOJ7QEU4E5RVK3/AFB66A48-8229-447D-8052-BDF7145A7E5C.JPG Newtown Square Built-ins The clients’ kids took an interest in what I was doing while I was there, pulling up their chairs to watch me work. At the end of the job they gave me this very nice ‘thank you’ card. http://www.greengatewoodworks.com/malvern-fireplace-surround daily 0.75 2021-05-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621280233573-KQPHH61Q2J1EQBA868TI/IMG_4822-2.jpg Malvern Fireplace Surround A repeat client had this small fireplace surround in their home, and they asked me to remove this and create a larger surround. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621280233573-KQPHH61Q2J1EQBA868TI/IMG_4822-2.jpg Malvern Fireplace Surround A repeat client had this small fireplace surround in their home, and they asked me to remove this and create a larger surround. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621280233375-IO9K8YFHCNTMXB74LPSN/IMG_4875-2.jpg Malvern Fireplace Surround The finished surround goes floor-to-ceiling, has a 2” thick black walnut mantle, and is trimmed out in a simple shaker style. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621280234617-LXATBAD0AGDAAJ4BAIH1/IMG_4877.jpg Malvern Fireplace Surround The black walnut I selected for this project had great grain and colors as you can see in this photo. http://www.greengatewoodworks.com/penn-valley-builtins daily 0.75 2021-11-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636388288424-W6KTMM6YRSOE25CEHLY6/IMG_6453+2.jpg Penn Valley Built-ins A repeat client asked me to create a set of built-ins including a window seat in her living room as part of a large remodeling job she was undertaking. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636388288424-W6KTMM6YRSOE25CEHLY6/IMG_6453+2.jpg Penn Valley Built-ins A repeat client asked me to create a set of built-ins including a window seat in her living room as part of a large remodeling job she was undertaking. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636387640596-SBEVPZ60N1C8JD15R8ZQ/IMG_6453+2.jpg Penn Valley Built-ins A repeat client asked me to create a set of built-ins in her living room for additional storage that would also include a window seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636387640118-BSAMRKZK0YJH8M043SBO/IMG_6451+2.jpg Penn Valley Built-ins Here are the finished built-ins. They feature inset doors, lifted baseboards, and black walnut countertops and bench top. A large single drawer under the window seat provide additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636387640254-TN47HRQOYSF9X5FTSULN/IMG_6452+2.jpg Penn Valley Built-ins Behind each shelf are a row of LED tape lights that provide ambient lighting for the room and are controlled from a switch on the other side of the room. http://www.greengatewoodworks.com/berwyn-storage-room-door daily 0.75 2021-11-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386278992-W8VUCRZ6CZB97YJ0CABU/82D15946-CDD4-404D-9DCF-255E287AF19A.JPG Berwyn Storage Room Door Chrissy McDonnell from Doyle & McDonnell, Inc came to me with a job to build a new door for a storage room on one of her client’s properties. The door in question was in bad shape, and the client wanted to match the style of their courtyard entry door, shown in the picture above. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386278992-W8VUCRZ6CZB97YJ0CABU/82D15946-CDD4-404D-9DCF-255E287AF19A.JPG Berwyn Storage Room Door Chrissy McDonnell from Doyle & McDonnell, Inc came to me with a job to build a new door for a storage room on one of her client’s properties. The door in question was in bad shape, and the client wanted to match the style of their courtyard entry door, shown in the picture above. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386854434-Q9003J9JB7S4J9K6PVYS/2EBB1E89-915B-498E-9553-455F78106615.JPG Berwyn Storage Room Door After taking measurements from the courtyard door, I started making up the frame for the new storage room door. I used solid white oak for all the components since it will be an exterior door, and I beaded the frame to match the style of the courtyard door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386355615-8Q0Y5UI7BNYTC6KCJO40/IMG_5397.jpg Berwyn Storage Room Door After the beaded panels were installed, I added the upper grid and clamped the door up for final assembly. Plywood clamping jigs like the one seen here make life much easier when trying to clamp up a curved surface. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386355657-1PKIWWVSKS8X9YPE47EY/IMG_5475.jpg Berwyn Storage Room Door Prior to installation I painted the door using an oil-based primer and then several coats of exterior paint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386279928-NHHR821I0O0KSU2RAUH7/666E5E9D-23C3-466D-A124-FA7E2F61208E.JPG Berwyn Storage Room Door Here the door can be seen in it’s final home. I built new jambs, reused the latch and handle from the original door, and added dummy strap hinges to match the courtyard door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386280274-3B1KZ6CJZZRFH0NL5CVU/12163736-9B39-4C04-B7F5-0D9A9AE8A1E5.JPG Berwyn Storage Room Door A wider shot showing the final product. http://www.greengatewoodworks.com/warrington-office-builtins daily 0.75 2021-11-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389505192-NOTVH6BRBWDFG348A3RH/IMG_6437.jpg Warrington Office Built-ins I was hired to make a set of office built-ins for a client, and they wanted to have a live-edge slab for the countertop. I found this large white oak slab which would fit the bill, but because it was so big I couldn’t fit it in my shop. My wife had to go up on the roof deck to take this picture to get it all in one shot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389505192-NOTVH6BRBWDFG348A3RH/IMG_6437.jpg Warrington Office Built-ins I was hired to make a set of office built-ins for a client, and they wanted to have a live-edge slab for the countertop. I found this large white oak slab which would fit the bill, but because it was so big I couldn’t fit it in my shop. My wife had to go up on the roof deck to take this picture to get it all in one shot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389358679-C6JLFJVHDNF3AWP7ID5Y/IMG_6497.jpg Warrington Office Built-ins Getting the large finished countertop into the house by myself took a little bit of creative thinking. I built these trucks from some materials I had laying around the shop which made the job a lot easier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389405429-O7HLDX5QRO4GN67I3NXA/IMG_6499.jpg Warrington Office Built-ins Getting the countertop in place was a bit of work as well. I set a block high on the side wall temporarily to give myself a chance to take a break and reposition myself for the final phase of lowering it place. Careful templating ahead of time makes it possible for me to fit large pieces like this in one shot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389359519-XTCTORZI1FZDKP9RT1HK/IMG_6437.JPG Warrington Office Built-ins https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389360094-QKQEGAXV7U0NAEMI7XKW/IMG_6713.JPG Warrington Office Built-ins Painted in Benjamin Moore color Flint, the finished product features inset doors, adjustable shelves, and oil-rubbed bronze hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389360887-3EGRO59B9PG830BBJJH3/IMG_6756.jpg Warrington Office Built-ins A closer shot of the finished live-edge countertop. http://www.greengatewoodworks.com/warrington-mudroom-lockers daily 0.75 2021-11-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636394845836-8FOREQAPGSDFC43HG4RP/IMG_6659.jpg Warrington Mudroom Lockers A repeat client hired me to create a set of lockers for their mudroom. The walls angled back in a way that made fitting 5 lockers in the space challenging, but not impossible. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636394845836-8FOREQAPGSDFC43HG4RP/IMG_6659.jpg Warrington Mudroom Lockers A repeat client hired me to create a set of lockers for their mudroom. The walls angled back in a way that made fitting 5 lockers in the space challenging, but not impossible. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636395095394-KTMVD13TZ765529P65UW/A35A2AAB-8D09-4A75-BAF2-0CE933EE1BD3.JPG Warrington Mudroom Lockers For the bench top I used reclaimed red oak barn wood. Finished with only a clear coat to preserve the character of the wood, it really turned out great. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636394845047-L7CNOZZ8DVYL2YDL1AQ0/B2B0CDB6-1498-4BEC-A3A3-C15FC34DB02A.JPG Warrington Mudroom Lockers The finished product. It has inset doors on the lockers, inset drawers below the bench, and an open spot above for baskets to hold smaller items. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636394844209-IRE95LCMHOCDFVGHUKT4/6A8D1566-5A30-4E17-978B-F561E4A08616.JPG Warrington Mudroom Lockers Another shot of the finished product from the kitchen. The raised trim details on the doors and drawer fronts was used to match the nearby kitchen cabinetry. http://www.greengatewoodworks.com/my-laundry-room daily 0.75 2026-02-13 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396813401-708KG0L580CEGNSXIR8Q/IMG_5649.jpg My Laundry Room My own laundry room renovation was a project that was a few years in the making, and much more involved than my normal built-in projects. Our plans included installing a reclaimed brick floor, so the first step was to clear the room out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396813401-708KG0L580CEGNSXIR8Q/IMG_5649.jpg My Laundry Room My own laundry room renovation was a project that was a few years in the making, and much more involved than my normal built-in projects. Our plans included installing a reclaimed brick floor, so the first step was to clear the room out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396822165-A4EPCAZ8QNDT82BXYEC9/IMG_5656.jpg My Laundry Room A layer of tar paper and wire mesh is installed prior to laying the wet bed for the bricks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396819417-EW5EJN1VUOLL91BYAIVM/IMG_5726.jpg My Laundry Room A base layer of mortar, the wet bed, is installed over the wire mesh, and the whole thing is pitched towards a drain in the neighboring mudroom. This is to drain water out quickly if the washing machine ever springs a leak. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396823048-0ICI9DO4HK7YT5B2OJEQ/IMG_5787.jpg My Laundry Room In addition to the slope of the floor, I added a waterproof barrier on top of the wet bed to aid with drainage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396826792-84J085OO2SKRQHN3DEWU/IMG_5857.jpg My Laundry Room Next up was installing the reclaimed bricks in a basketweave pattern. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396829552-FBZDGN8BL005MH0JEO5L/IMG_8405.jpg My Laundry Room After the bricks were installed, I sealed the bricks, then grouted everything. This protected the bricks from getting stained by the grout. Once the grout was cleaned up, I applied multiple additional layers of sealant to the entire floor. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396828329-2CJT3X26PVROBUAY305G/IMG_7903.jpg My Laundry Room After the floors were in, I added a wainscot ceiling. This portion of our home was original a porch, and we decided to maintain that character when we renovated, hence the brick floors and this ceiling. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396810654-MFAKSMY9D484BV5YEZS3/IMG_4234.jpg My Laundry Room With the brick floors and ceiling done for the time being, I moved the washer and dryer back into the room while I worked on the final cabinet design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396807008-OBCXZWCTO3SY447T4WKP/B7425CF5-25DB-4FCE-B933-881A715B3A6D.JPG My Laundry Room This was the design I came up with for the room. Given the sloped ceiling and the uneven brick floors, the installation was going to be a challenge, but I enjoy projects like that. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396812141-YBYY80G0M7R0DOLWB4AF/IMG_4272.jpg My Laundry Room After installing the cases it was time to template for the countertop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396807775-N4DKICD8OJRF44S2AJWH/C3C15908-CC58-49FA-980B-F22CAF904B85.JPG My Laundry Room The finished project. The upper cabinets are angled to follow the slope of the ceiling, and the doors are angled as well to maintain a constant width between the top of the doors and the ceiling. This was done to leave room for the track which will be used for a future rolling ladder to allow easier access to pull out shelves in the upper cabinets. LED lights under the upper cabinets provide soft ambient lighting in the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396806231-RN33A29GM5GK7K0RLNTV/21B9DC0D-FDAA-4134-BDC7-874AB2A170F2.JPG My Laundry Room A large 30” farm sink provides ample room for soaking clothes, and next to the sink base is an open area for storing the laundry sorter. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396805553-7L3ZDXMRQ8XY963BHYH7/5FE590D4-1AFD-4B1C-AB33-0886F7FC4B1A.JPG My Laundry Room On the left side of the room is a false cabinet that conceals a laundry chute which originates upstairs in our master bathroom. Clothes pass through this false cabinet, down through the opening in the countertop, and then collect in a large pull-out drawer housed in the lower cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770943821715-SDX7BIPYFYOBQEXSPNKB/laundry+door+-+lightened.jpg My Laundry Room Between the laundry room and our mudroom, we installed this antique porch door as a pocket door. The original mail slot on the door added to the porch theme we were going for. http://www.greengatewoodworks.com/malvern-builtins daily 0.75 2023-10-03 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661706771179-ACXZ0P7BL7B4JCKDSTKJ/IMG_0065+2.jpeg Malvern Office Built-ins I was hired to create a set of built-ins for this client’s basement office. As you can see this was one of those times when I forgot to take a “before” picture and didn’t realize it until I had already gotten the lower cabinets installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661706771179-ACXZ0P7BL7B4JCKDSTKJ/IMG_0065+2.jpeg Malvern Office Built-ins I was hired to create a set of built-ins for this client’s basement office. As you can see this was one of those times when I forgot to take a “before” picture and didn’t realize it until I had already gotten the lower cabinets installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661706837444-M4FF0P55H6HUVU9XS48M/IMG_0100+2.jpeg Malvern Office Built-ins After the lower cabinets were set, I fit and installed the countertop, and then installed the upper cases. After that I fit and hung the doors, installed the trim pieces, and painted everything to match the existing trim color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661706772969-BTYPVAYER2MTZ2H4B7H1/IMG_0184+2.jpeg Malvern Office Built-ins The finished product features inset flat-panel doors, a black walnut countertop, and a pull-out shelf inside the lower center cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661706772232-3VBBCBGU8HC90XSMTMOO/IMG_0179+2.jpeg Malvern Office Built-ins LED lights under each shelf provide additional lighting to the office. http://www.greengatewoodworks.com/merion-station-pair-of-built-ins daily 0.75 2022-08-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701707050-ZDJBBKI8GVCR38P5CUZ1/IMG_8809.jpg Merion Station Pair of Built Ins I was hired to create a pair of built-ins in this client’s living room. One unit will go here with the other on the opposing wall across the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701707050-ZDJBBKI8GVCR38P5CUZ1/IMG_8809.jpg Merion Station Pair of Built Ins I was hired to create a pair of built-ins in this client’s living room. One unit will go here with the other on the opposing wall across the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701607153-ZECWTIZ41Y933H8RFXJS/456645FB-1B87-4143-AAC0-056FDAC4768F.JPG Merion Station Pair of Built Ins These built-ins are the larger of the pair and features flat panel doors and drawers, and black walnut countertops. The kids of the house were staking claims to the window seat even before it was finished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701606471-N6PXX7OD9ADI1LO7Q90U/5BD56C38-3DAE-4448-9A7B-229CB974B026.JPG Merion Station Pair of Built Ins The built-ins also feature LED lights under the shelves which provide a soft light for the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701707018-6HPEQ1OJWT4GCORGUTKQ/IMG_8804.jpg Merion Station Pair of Built Ins This was the space on the opposite side of the room before I got started. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701606383-8R4ARKVJK34Q9SQTH41S/4D6DBB03-4DC6-4EDE-A5FC-CBE4E199DE52.JPG Merion Station Pair of Built Ins The finished built-ins feature the same flat panel doors and drawers as the other set, as well as a matching black walnut countertop. The open area of the countertop serves as a “launch pad” in the morning for the adults of the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701607015-MXJ4NE6HMKV38K5EUIIA/08FADFEC-BB0B-4487-9B25-772923A84BB5.JPG Merion Station Pair of Built Ins This unit has dimmable LED lights under the shelves as well. http://www.greengatewoodworks.com/philadelphia-banquette daily 0.75 2022-08-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661707666208-0R653KSMS0QQUZCZW83S/55E1CE2B-AF3F-4508-901E-01AE18BD0244.JPG Philadelphia Banquette For this job I was hired to create bench seating and create storage space for a growing family. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661707666208-0R653KSMS0QQUZCZW83S/55E1CE2B-AF3F-4508-901E-01AE18BD0244.JPG Philadelphia Banquette For this job I was hired to create bench seating and create storage space for a growing family. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661707666354-S533Q802I7MR6G0VK27Z/C5756807-6D4C-4EF4-9FC7-435911AE0B65.JPG Philadelphia Banquette The finished banquette offers plenty of seating while also providing storage in two ways - drawers in the end of the side benches, and trunk storage in the rear bench. http://www.greengatewoodworks.com/haverford-french-door-conversion daily 0.75 2022-08-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704519410-HPZ0QB0S7IVOUJYS9YFT/IMG_0262.jpeg Haverford French Door Conversion A repeat customer asked me to rebuild this pair of french doors for them. After some discussion they decided to change it to a single door instead of a pair of doors, but they wanted to maintain the look of the original doors as much as possible. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704519410-HPZ0QB0S7IVOUJYS9YFT/IMG_0262.jpeg Haverford French Door Conversion A repeat customer asked me to rebuild this pair of french doors for them. After some discussion they decided to change it to a single door instead of a pair of doors, but they wanted to maintain the look of the original doors as much as possible. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704525114-0B6UHPM1QGRZXCYMDWRL/IMG_0806.jpeg Haverford French Door Conversion My solution was to create a large single door that would have all the same trim details making it look like a pair of doors from outside. Built from solid white oak, the door was painted with several layers of oil-based primer and then several coats of exterior grade paint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704515476-MVTBO0OG5GT577K7L78G/67951049718__080B9BEB-1DFA-42CA-91B9-FBDB24808427.jpeg Haverford French Door Conversion The original doors had thin, single-pane glass which provided little to no insulation and were notoriously leaky in the winter. I upgraded the glass in the new door by using these custom made glass inserts that are filled with argon gas. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704533410-RY5PKZ2ZFA54NY1PL89H/IMG_0883.jpeg Haverford French Door Conversion After painting the door I delivered it for installation. A few years earlier I had bought a pair of door dollies, seen here, which make installation of large heavy doors a breeze. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704545572-LLDP85TSQGPAWCM817V8/IMG_0905.jpeg Haverford French Door Conversion The installed door provides a larger opening than the original pair of doors, making the space more usable for the client. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704547320-TMDOENLW1KP7HKKORC4P/IMG_1109.jpeg Haverford French Door Conversion The location of the new knob and deadbolt are the only thing that gives away that this is now a single door. http://www.greengatewoodworks.com/emmet-brickowski-cabinet daily 0.75 2022-10-15 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661733224340-038G4XNCAAV65KPZWD52/IMG_9558.jpeg Emmet Brickowski Cabinet Several times over the years I had made items to be auctioned off for my daughters’ nursery school fundraiser where the parents of each class put together a raffle basket based on a theme (“reading”, “wine”, “coffee lover” have been themes in the past for example). For my younger daughter’s final year at the school, I knew I needed to go big with my donation so I reached out to her teacher early in the school year to start thinking of ideas. I asked her what the theme would be this year and she threw out several options until she said “we could always do LEGO, the kids love that”. As a life-long fan of LEGO, I jumped on that one. I immediately envisioned a giant lego figure that was also a cabinet and quickly sketched the drawing above. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661733224340-038G4XNCAAV65KPZWD52/IMG_9558.jpeg Emmet Brickowski Cabinet Several times over the years I had made items to be auctioned off for my daughters’ nursery school fundraiser where the parents of each class put together a raffle basket based on a theme (“reading”, “wine”, “coffee lover” have been themes in the past for example). For my younger daughter’s final year at the school, I knew I needed to go big with my donation so I reached out to her teacher early in the school year to start thinking of ideas. I asked her what the theme would be this year and she threw out several options until she said “we could always do LEGO, the kids love that”. As a life-long fan of LEGO, I jumped on that one. I immediately envisioned a giant lego figure that was also a cabinet and quickly sketched the drawing above. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661733222137-D8RA3LD4BBG1H25VIDJY/IMG_7079.jpeg Emmet Brickowski Cabinet First and foremost I wanted to make sure that everything was proportional to a true LEGO figure, so I got out my digital calipers and started measuring every aspect of the figure. Then I used a spreadsheet to scale up the dimensions based on a few different final height options. Initially I had planned on just building a generic lego figure as seen here, but a few weeks into it I realized there was one figure that the kids would love more than anything else. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661732011241-DPYSHUP94OVP5SPP78VO/1F669C34-6A5D-4034-B76A-4768F7039326.JPG Emmet Brickowski Cabinet And that’s how I ended up building a giant Emmet Brickowski from The LEGO Movie. This Emmet is over 36 times larger than the actual figure. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661732011917-NBUAY57PCQ32BROESEF6/4A6B6ECE-A232-40AC-B862-E9C0F7CCA37C.JPG Emmet Brickowski Cabinet Emmet’s legs, torso, and head open up for storing your LEGOs inside, and, in order to be as accurate as possible, both the arms and hands rotate like an actual LEGO figure. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661732012747-CQCZPBLBI2R1FBRNGTQ5/48FB7DDB-690F-4206-B783-A28131D011A6.JPG Emmet Brickowski Cabinet All said and done, Emmet stands a little over 60” tall as shown here with me for scale. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661733213026-BO204F1BS2JAQSMHF1OM/IMG_0045.jpeg Emmet Brickowski Cabinet Emmet ended up raising a good amount of money for the school and at the end of the day one of the kids from my daughter’s kindergarten class was the winner. As you can see here, he and his older brother were very excited about it. This was a super fun project and I’m already toying with the idea of making another giant LEGO man for my shop, based on the figure I made of myself when I built a scale model of my own house from LEGOs for my kids. http://www.greengatewoodworks.com/newtown-square-mudroom-builtin-and-wall-alcove1 daily 0.75 2023-01-15 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673812574647-BYBOTMJSOMI310C90P5M/6771E1BC-6B4C-4E0B-901B-87340F1A466B.JPG Newtown Square Mudroom Built-in and Wall Alcove A client asked me to create a new set of built-ins in their mudroom. The space was a little restricted due to the existing doorways, but there was a small recessed alcove on the opposing wall that created more opportunities for hanging storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673812574647-BYBOTMJSOMI310C90P5M/6771E1BC-6B4C-4E0B-901B-87340F1A466B.JPG Newtown Square Mudroom Built-in and Wall Alcove A client asked me to create a new set of built-ins in their mudroom. The space was a little restricted due to the existing doorways, but there was a small recessed alcove on the opposing wall that created more opportunities for hanging storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673812575417-4CFJ5FSAOO1KSLBHSPE4/A882DDF8-3BE7-4D44-B338-3644BEA20015.JPG Newtown Square Mudroom Built-in and Wall Alcove Here is the finished built-in unit. It features a black walnut bench, open shoe cubbies underneath, closed storage above, and a stack of additional cubbies on the side that were designed around baskets the client had picked out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673812574369-M9BLHL21EDH4D1ALV7Q5/153AC213-0197-44D0-A208-5EE6C4E9B326.JPG Newtown Square Mudroom Built-in and Wall Alcove For hardware, the client found these bent railroad spike hooks from an online retailer, and they gave the built-ins a unique characteristic. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673812575534-ILPUEEEHK5JFCHKK9HAM/IMG_2733.JPG Newtown Square Mudroom Built-in and Wall Alcove The recessed alcove on the opposing wall has the same railroad spike hooks, and a black walnut shelf and custom-made wainscoting to match the built-ins. Photo credit: Melanie Lemke http://www.greengatewoodworks.com/secret-bookcase-door daily 0.75 2023-01-15 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673816042245-D9YL682SVL38ZBE4SDND/IMG_1178.jpg Secret Bookcase Door A client I’ve done a few projects for contacted me to see if I’d be up for making a secret bookcase door. I love odd projects like this, so I jumped at the opportunity to do it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673816042245-D9YL682SVL38ZBE4SDND/IMG_1178.jpg Secret Bookcase Door A client I’ve done a few projects for contacted me to see if I’d be up for making a secret bookcase door. I love odd projects like this, so I jumped at the opportunity to do it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673816045074-ZKB4WLRCEH0L6J13FG57/IMG_1154.jpg Secret Bookcase Door After studying the hardware kit and its requirements, I built the bookcase and then did the finish trim work after I got it installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673816035911-6824SJOYP0Z3LRDFW3ZW/4FB37930-054D-4DE5-9EBB-B597DFE7AEEB.JPG Secret Bookcase Door Here is the finished bookcase. The book on the shelf is part of the latch mechanism that releases and opens the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673815958816-82ZF11GZMRPDGKNHNYYW/ezgif-3-e358dd5b12.gif Secret Bookcase Door Here is a gif of it in action. When opened it allows access to a walk -in closet. http://www.greengatewoodworks.com/chester-springs-dining-room-builtins daily 0.75 2023-01-19 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674082434719-VHD2VO0BZNNPK7D45L9N/IMG_1966.jpeg Chester Springs Dining Room Built-ins For this project the client was looking to create more storage in their dining room, as well as a wine storage area above the new window they’d had installed prior to me beginning my work. As part of this project I also created a platform bed at their request for additional storage in their bedroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674082434719-VHD2VO0BZNNPK7D45L9N/IMG_1966.jpeg Chester Springs Dining Room Built-ins For this project the client was looking to create more storage in their dining room, as well as a wine storage area above the new window they’d had installed prior to me beginning my work. As part of this project I also created a platform bed at their request for additional storage in their bedroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674082434296-55WKYVDEY2FOL0D3KFED/IMG_1972.jpeg Chester Springs Dining Room Built-ins These two support jacks came in handy when setting the wine rack cabinet. They’re an invaluable tool when you work alone like I do. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674082455708-HTEL3RQ7G3VC98HTTHHK/IMG_1993.jpeg Chester Springs Dining Room Built-ins With all the cases set and the doors/drawer installed, I painted the final finish coats. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674082457216-8IELK50WLLWO0F1HLDC7/IMG_2209.jpeg Chester Springs Dining Room Built-ins The finished product has flat panel overlay doors and drawers, and the entire piece frames their dining room window quite nicely. The lighting in this room wasn’t great for pictures so I had to lighten it a bit afterwards with editing software which is why this picture looks a bit grainy. http://www.greengatewoodworks.com/chester-springs-bed-platform daily 0.75 2023-01-19 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674134070950-E00TG84QGBALFI74ZMV9/IMG_2009.jpg Chester Springs Bed Platform As part of this project, the client asked me to also create a storage platform for under their bed. For some reason I didn’t get any photos during the construction phase, the only ones I have start with this one taken during installation. The platform consists of 3 drawer bases with a center support panel, and I custom-made hardware to attach it to their existing headboard. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674134070950-E00TG84QGBALFI74ZMV9/IMG_2009.jpg Chester Springs Bed Platform As part of this project, the client asked me to also create a storage platform for under their bed. For some reason I didn’t get any photos during the construction phase, the only ones I have start with this one taken during installation. The platform consists of 3 drawer bases with a center support panel, and I custom-made hardware to attach it to their existing headboard. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674133939183-5YQSKXBQHVJHT9SIMZUA/IMG_2211.jpeg Chester Springs Bed Platform The finished bed, reassembled. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674133957895-A9OBRZWAQ1NUW3I2AIMQ/IMG_2212.jpeg Chester Springs Bed Platform There are 6 total drawers under the bed, 2 one each side adn 2 at the foot of the bed. The drawers are all made from solid maple with housed rabbet joints in the corners, reinforced with walnut dowels, and mounted on soft-close undermount drawer slides. http://www.greengatewoodworks.com/media-builtins daily 0.75 2023-01-18 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674081211283-KCCTEWSZCBWWYA7O24X3/IMG_7129+2.jpg Media Built-ins For this project the client was looking to create new storage space in their living room to replace their existing free-standing bookcases. This is the before picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674081211283-KCCTEWSZCBWWYA7O24X3/IMG_7129+2.jpg Media Built-ins For this project the client was looking to create new storage space in their living room to replace their existing free-standing bookcases. This is the before picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674081133720-3LGB9T8N6QBUGXEJXNWL/4DC77694-70AE-4E7A-A831-8E6FD567BECC.JPG Media Built-ins The finished product is a series of lower cabinets and bookshelves in a classic Shaker style with black walnut countertops and bench top. New outlets were added inside the bookshelves for holiday decorations, and one outlet was added above the window seat for phone/laptop charging. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674081134859-KKA1HXBQ2YAIWDK99BCZ/8002E1A5-A453-4D14-A223-AE5FF7C1B400.JPG Media Built-ins The window seat creates a nice seating area with trunk storage below. The HVAC duct in the before photo has been relocated and extended to exit through the new baseboards. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674081133721-M3HZRKFROKN7UOBBNQGO/A35E45F6-1BC7-4651-B517-3794048E2FDE.JPG Media Built-ins Set on hidden Soss hinges, the bench top lid was cut from a single large blank, which allows the grain of the walnut to continue seamlessly across the entire length of the top. http://www.greengatewoodworks.com/new-gallery-45 daily 0.75 2023-10-03 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696369643540-9SD766YXO6QMEZJCF0AT/Graves4.jpg Valley Forge Banquette For this project the client was looking for a way to make this corner of their first floor more useful as a seating area and a mini-mudroom of sorts by their entry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696369643540-9SD766YXO6QMEZJCF0AT/Graves4.jpg Valley Forge Banquette For this project the client was looking for a way to make this corner of their first floor more useful as a seating area and a mini-mudroom of sorts by their entry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696369642917-XMT0EYOCIY31G1K0VW65/Graves1.jpg Valley Forge Banquette The finished product features black walnut bench tops on the banquette, bookshelves behind and a coat rack area right next to the entry door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696369625799-TIQ5XFGVR9ZOQO2FS5UP/Graves2.jpg Valley Forge Banquette The benchtops open up for additional storage inside the banquette, and under-shelf lighting in the bookshelves provides a nice ambient light for the area. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696369642937-DMFAIE0WH8AXOCH1N49N/Graves3.jpg Valley Forge Banquette A close up of the hanging area. A double row of hooks is mounted on black walnut boards to match the benchtops, the shelf above provide additional storage for smaller items, and it’s all mounted on custom wide wainscot paneling. http://www.greengatewoodworks.com/malvern-builtins-2 daily 0.75 2023-10-03 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371300361-2KYABVDF83IM4WJFVUBQ/Clark4.jpg Malvern Built-ins Often times when creating built-ins, I’ll fill an entire wall, but in this case the client wanted to do only a section of their living room wall to act as a focal point, while providing a nice spot for their TV and additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371300361-2KYABVDF83IM4WJFVUBQ/Clark4.jpg Malvern Built-ins Often times when creating built-ins, I’ll fill an entire wall, but in this case the client wanted to do only a section of their living room wall to act as a focal point, while providing a nice spot for their TV and additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371324877-X7W6GBD293DBVFB5H1C2/clark1.jpg Malvern Built-ins The finished project has inset flat-panel beveled shaker doors, beaded face frames, and a black walnut countertop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371324899-VEOWML6AG92ZA3IY1L2V/clark2.jpg Malvern Built-ins Under-shelf lighting add a soft ambient glow in the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371300340-ROSB0FUNEBDM5WQBUXUY/Clark3.jpg Malvern Built-ins Beaded face frames as a subtle detail in a project that give it a classic look. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371301007-PRQT1PVINTVO7FZ54PFJ/Clark5.jpg Malvern Built-ins The client was kind enough to send us a photo of the built-ins after they had gotten them decorated, and it really turned out great. http://www.greengatewoodworks.com/st-matthews-school-sign daily 0.75 2023-10-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696465251356-7ZFQQGJLMENBHJHBFXSN/St+Matts1.jpg St Matthew's School Sign When my kids went through the St. Matthew’s School a few years ago, it was a tradition of sorts for families to take their “first day” photos by a small sign on the walkway to the school. The school contacted me about making a new one for the school’s 20th anniversary, so I created this design based on the characters in the school’s logo. The “first day” panel is held in place with magnets and can be exchanged with one that reads “last day.” The numbers use the same magnet system and can be updated for each school year. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696465251356-7ZFQQGJLMENBHJHBFXSN/St+Matts1.jpg St Matthew's School Sign When my kids went through the St. Matthew’s School a few years ago, it was a tradition of sorts for families to take their “first day” photos by a small sign on the walkway to the school. The school contacted me about making a new one for the school’s 20th anniversary, so I created this design based on the characters in the school’s logo. The “first day” panel is held in place with magnets and can be exchanged with one that reads “last day.” The numbers use the same magnet system and can be updated for each school year. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696465263384-BKBQT1ILG6CR04HHVRJ9/St+Matts2.jpg St Matthew's School Sign I included enough extra numbers, so the school will be set for the next 100 years or so. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696465263461-MCJMZPRMQ077RB84M4K4/St+Matts3.jpg St Matthew's School Sign After dropping it off, the director of the school, Sandy Elkins, was kind enough to model for us. http://www.greengatewoodworks.com/malvern-staircase-slide daily 0.75 2023-10-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696466701512-J5QZVZK9G2ITFR3V45V9/IMG_3628.jpg Malvern Staircase Slide Every now and then a client brings me a super fun/weird project outside my typical cabinetry jobs, and this was one of the best. This client had put up homemade slides for her kids in the past but wanted something a bit safer and with a smoother transition at the bottom. The first step for me was to take detailed measurements of the existing staircase, then draw the entire thing out to scale and start figuring out the sizes of each section. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696466701512-J5QZVZK9G2ITFR3V45V9/IMG_3628.jpg Malvern Staircase Slide Every now and then a client brings me a super fun/weird project outside my typical cabinetry jobs, and this was one of the best. This client had put up homemade slides for her kids in the past but wanted something a bit safer and with a smoother transition at the bottom. The first step for me was to take detailed measurements of the existing staircase, then draw the entire thing out to scale and start figuring out the sizes of each section. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696466807952-FP3JQMWD1SE4UNTG3UZP/IMG_3684.jpg Malvern Staircase Slide This is the bottom “transition” section before I applied the top layers of plywood. Each section of the slide has multiple ribs inside for structural stability. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696466051107-KZB340NYQBGCQ58IIHCZ/slide2.jpg Malvern Staircase Slide A before picture of the staircase. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696466051070-OJDLIBUMMM9B9JUJKQNQ/slide1.jpg Malvern Staircase Slide The finished slide consists of five different sections that interlock with each other. They are secured to the stair risers using threaded inserts, so it can be quickly installed or disassembled for storage in just a few minutes. http://www.greengatewoodworks.com/shop-door-rebuild daily 0.75 2024-11-03 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641870161-H12ZW9LLXKMNHFQC1RYL/IMG_7111%2B2.jpg Shop Door Rebuild I’ve been wanting to build some new doors for my shop for a while to replace the temporary plywood ones shown here, but the material costs were a bit prohibitive so I started searching around for alternatives. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641870161-H12ZW9LLXKMNHFQC1RYL/IMG_7111%2B2.jpg Shop Door Rebuild I’ve been wanting to build some new doors for my shop for a while to replace the temporary plywood ones shown here, but the material costs were a bit prohibitive so I started searching around for alternatives. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641460037-WBVEPVVSRLFL5JGA9D93/IMG_8024+2.jpg Shop Door Rebuild I found this pair of old barn doors that were the perfect width for what I needed, the only problem was they were about a foot too tall so I’d have to cut them down and rebuild the bottom portion of each door. The next series of photos will show the process in depth. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641382407-SGSMLDUQMME5QKF0JYCL/IMG_8123.jpg Shop Door Rebuild First step is cutting the door to its final height using the track saw. I use the track saw instead of trying to push the door across my table saw because it’s more accurate and safer to do it this way. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641386389-W72L5VMVZX00HSQA1DHA/IMG_8124.jpg Shop Door Rebuild After the bottom portion of the door is removed I needed to remove the pieces of the stiles (the vertical elements of the door) and the bits of the center panels so I could isolate the bottom rail (horizontal elements of the door). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641396632-CGJ7Y21HQUA4SVJGYGYK/IMG_8128.jpg Shop Door Rebuild Here you can see the rail after I removed the extraneous pieces. After this I cut off the original extended tenons from the rail (those “ears” that are sticking out on each side). Those extended tenons help increase the structural rigidity of the door, but I can’t reuse them in this case without completely taking the door apart which I didn’t want to do, so I’ll reinforce that area of the door in a later step. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730642420356-N3UTWVUO2DTUD798GYRJ/IMG_8129.jpg Shop Door Rebuild Next step is to measure the height of the bottom rail so I know where to make my next cuts on the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641404486-USITC84Z22YZBI9WCK12/IMG_8132.jpg Shop Door Rebuild Using my track saw again, I line up the track with the bottom rail height measurement and then cut out the center of the door, making sure not to cut the outer stiles of the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641414146-6EHY5QTLUOHNMELXRVQI/IMG_8136.jpg Shop Door Rebuild After making the cut, I remove the cut off pieces of panel and inner stiles. This space is where the bottom rail will go. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641421023-A5F8YLE1QT3D05KMYEA4/IMG_8137+2.jpg Shop Door Rebuild This door was originally built with a rail-and-stile technique where the rails and stiles have interlocking profiles to nestle together snugly. In this case, the original builder used a rounder profile, and luckily I had the matching router bit sets already in my tool collection. I used my festool router to cut the rail profile into the ends of the inner stiles. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641420206-KVX6M5UHNND6AZY6XIPU/IMG_8139+2.jpg Shop Door Rebuild Here you can see the rail profile, which is just the inverse of the stile profile cut. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641428974-S7X9UB71S7ASTFIDQMLF/IMG_8141+2.jpg Shop Door Rebuild The original panels were tapered at the bottom in order to slide into the bottom rail, but since I cut them off I removed that tapered bit and had to redo it. I started out with a straight bit in my laminate trimmer to remove the bulk material. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641435030-3MINSUVPDTSYXKCJ19KM/IMG_8143+2.jpg Shop Door Rebuild With the bulk material removed, I used my chisels to taper the ends so they’d slide nicely into the bottom rail. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641435610-X396D50SZB3QCZYSA90Q/IMG_8150+2.jpg Shop Door Rebuild The bottom rail is now ready for a dry fit to test everything out and check for any last minute adjustments that may be needed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641373401-29MJ424G5BF4FSUORGYI/IMG_8107.jpg Shop Door Rebuild I mentioned earlier how I would need to reinforce the door structure since I had removed the original extended tenons from the bottom rail. I added four of these long floating tenons (or “dominoes”) on each side of the door using my festool domino joiner. These dominoes are made from sapele, a tropical wood that’s good for use outdoors. I could probably get away with the standard beech dominoes, but I had these sapele ones on hand and it never hurts to overbuild things. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641376521-RNXEFV0388S8CAAH5PI7/IMG_8114.jpg Shop Door Rebuild Each side of the door gets four of these dominoes which are driven in from the outside, glued in place, then clamped overnight. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641442567-VNWIJH144RC69L0Z4ZBN/IMG_8151.jpg Shop Door Rebuild This is the rebuilt door reassembled and ready for the next stages. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641380226-3QTC7X30OVHTVGPM94CT/IMG_8117.jpg Shop Door Rebuild Here you can see the difference in height. The original doors were around 108” tall and ended up around 94” tall when I was done. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641442843-6PPVW8HRFJ5HTUM1TRUV/IMG_8162.jpg Shop Door Rebuild Once I was done with one door, I repeated the process with the second door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641450837-OXDXMY6956FWK0N85D2Y/IMG_8813.jpg Shop Door Rebuild The finishing process involved some epoxy work to fill a few voids, then a lot of sanding to remove the old paint as much as possible. Then I did 3-4 coats of oil-based primer, and finished the doors off with an exterior grade topcoat. Because these doors were so large, I couldn’t attach the full jambs ahead of time and install them as a pre-hung unit. Instead, I attached a jamb to each door, then moved them into place with my dollies. If you’re working with large heavy doors, these dollies from Door Stud are invaluable, especially if you work alone like me. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641451450-DOTWD17X095P2BWDNUFC/IMG_8896.jpg Shop Door Rebuild After I got each door into position, I secured the jambs to the framing, installed the upper jamb, and then put on the hardware. After that I replaced some missing and broken glass in these doors with antique glass that was salvaged from a friend’s 1860’s era home near my shop. I don’t know the age of these doors, but the original glass was fairly wavy and the antique glass I used was a great match. Last thing to do was install the exterior trim and capping. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641456668-IKK7QEQIH52JMKE8SB4Y/IMG_9166+2.jpg Shop Door Rebuild The final doors make a great addition to the shop. Next up will be installing a dark green vertical metal siding and then Chester County field stone to the cinder block portions of the walls to match the stone on our home. The color of these doors, Sherwin William’s “Kaffee” (SW6104), was chosen to complement that future field stone. . The original temporary doors I built had a dog door for Sydney but after all the work I did on these doors I couldn’t bring myself to cut a hole in them, so I moved her dog door to the back of the shop. http://www.greengatewoodworks.com/lafayette-hill-fireplace-builtins daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737646768287-D64BIU2HRSZSZXW0RS1D/27A77288-35CC-47EB-AE53-762AD20966BF.JPG Lafayette Hill Fireplace Built-ins This massive brick fireplace and hearth dominated the room, and the clients wanted to gain more storage while reducing the overall feel of the fireplace by installing built-ins. To cut out and remove the bricks would have been costly and very messy, so I decided to work around them instead. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737646768287-D64BIU2HRSZSZXW0RS1D/27A77288-35CC-47EB-AE53-762AD20966BF.JPG Lafayette Hill Fireplace Built-ins This massive brick fireplace and hearth dominated the room, and the clients wanted to gain more storage while reducing the overall feel of the fireplace by installing built-ins. To cut out and remove the bricks would have been costly and very messy, so I decided to work around them instead. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737646767459-MNVNO82IJGPYN2RD37K5/2CB32112-E67B-49F5-A6E7-A581857CD54A.JPG Lafayette Hill Fireplace Built-ins The finished built-ins were designed to wrap around and conceal the bricks underneath and behind, while still providing plenty of storage space. The cabinet on the right is just a standard cabinet, while the one of the left is a bit different. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737646769013-AUPQKD57MI2GR2T3JOJL/83F13923-5647-42C8-B5D7-F72BE901A898.JPG Lafayette Hill Fireplace Built-ins The left cabinet houses a large firewood drawer the client requested, and I faced it with two false doors to give a balanced appearance to the overall project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737647903361-I16YRXWAER08N30TYD9P/8E33C201-3D23-4A24-B17B-DD9584A157B7-1+copy.jpg Lafayette Hill Fireplace Built-ins The clients were also kind enough to share this photo of the finished project after they had decorated. http://www.greengatewoodworks.com/bala-cynwyd-sideboard-and-shelves daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737648673365-H03GQETQ89T9JIVPCQNI/Kaplan1.jpg Bala Cynwyd Sideboard and Shelves Finding the right slab for a project is sometimes a Goldilocks situation. For this project - a sideboard for the dining area of a kitchen - I needed about 7’ of a live-edge white-oak slab. While searching for the right piece, I found some that had no character to the edge, while others had far too drastic of a curve to work. . https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737648673365-H03GQETQ89T9JIVPCQNI/Kaplan1.jpg Bala Cynwyd Sideboard and Shelves Finding the right slab for a project is sometimes a Goldilocks situation. For this project - a sideboard for the dining area of a kitchen - I needed about 7’ of a live-edge white-oak slab. While searching for the right piece, I found some that had no character to the edge, while others had far too drastic of a curve to work. . https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737649387433-XIE5N1V1BRIMTLMY6GK9/IMG_4167+2.JPG Bala Cynwyd Sideboard and Shelves Finding the right slab for a project is sometimes a Goldilocks situation. For this project - a sideboard for the dining area of a kitchen - I needed about 7’ of a live-edge white-oak slab. While searching for the right piece, I found some that had no character to the edge, while others had far too drastic of a curve to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737649590131-VGHMSIIRQFZ1KYEIUIKZ/IMG_4195+3.jpg Bala Cynwyd Sideboard and Shelves This one was just right: a gentle curve with some interesting features, great colors, and enough material left over to make matching shelves for the alcove. Finished with only a clear-coat and no staining, the natural colors of the wood really shine through. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737649589538-DMF0L16XZPXVT311DGK3/IMG_4193+3.jpg Bala Cynwyd Sideboard and Shelves https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737649590662-KG7RY0TINC3NG01LS7PM/IMG_5210+crop.jpg Bala Cynwyd Sideboard and Shelves With a starting length of 13’, this slab was a bit of a challenge to handle. I had to make up some new dollies just to move it around, and it required using my truck’s winch to unload it safely by myself. All worth it in the end though, as the project turned out beautifully. http://www.greengatewoodworks.com/bryn-mawr-living-room-builtins daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737650463001-LSAKZSHK728WQOYW0299/Screenshot+2023-10-01+at+9.26.35+AM+2.JPG Bryn Mawr Living Room Built-ins One of the benefits of having custom work done is that you can take the various components of a project into account ahead of time to figure out the proportions needed to make the whole design come together perfectly. In this case, the central section of the project was sized to accommodate the dimensions and requirements of the new gas fireplace, as well as the artwork above (which is actually a TV). I then designed and fabricated the built-ins and mantle to match those proportions and have the most efficient use of space for maximum storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737650463001-LSAKZSHK728WQOYW0299/Screenshot+2023-10-01+at+9.26.35+AM+2.JPG Bryn Mawr Living Room Built-ins One of the benefits of having custom work done is that you can take the various components of a project into account ahead of time to figure out the proportions needed to make the whole design come together perfectly. In this case, the central section of the project was sized to accommodate the dimensions and requirements of the new gas fireplace, as well as the artwork above (which is actually a TV). I then designed and fabricated the built-ins and mantle to match those proportions and have the most efficient use of space for maximum storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737650572662-GZDSYN67NSWDB59BSCIC/IMG_8785+2.jpg Bryn Mawr Living Room Built-ins Featuring inset flat-panel beveled shaker doors, beaded face frames, and chamfered columns, these built-ins and fireplace fill a once empty wall and really changed the feel of this room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737650571266-2OXK1UL97SEVEJ2DK4OB/IMG_3947+2.jpg Bryn Mawr Living Room Built-ins This is the “before” picture - all fireplace installation including framing, drywall, electrical, and the marble surround was handled by BTR Home Improvement and Construction (www.btrcustombuilders.com). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737650661212-LROV2PLH9MZWJZ96NTHK/IMG_7763.jpg Bryn Mawr Living Room Built-ins A while later I was back at that client’s home to discuss another project and got this shot of the fully decorated built-ins. http://www.greengatewoodworks.com/paoli-bookshelves daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737652602596-PUBCIXDURI0B971GJZGG/IMG_5295.jpg Paoli Bookshelves The client on this project contacted me because they were looking to solve a couple of issues they felt their living room had. It’s a somewhat narrow room with fairly low ceilings, and they wanted something that would draw the eye up to make the ceilings feel a bit higher without extending out into the room anymore than necessary. Their home was also lacking bookshelves, and they thought a floor-to-ceiling set of shelves would do the trick. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737652602596-PUBCIXDURI0B971GJZGG/IMG_5295.jpg Paoli Bookshelves The client on this project contacted me because they were looking to solve a couple of issues they felt their living room had. It’s a somewhat narrow room with fairly low ceilings, and they wanted something that would draw the eye up to make the ceilings feel a bit higher without extending out into the room anymore than necessary. Their home was also lacking bookshelves, and they thought a floor-to-ceiling set of shelves would do the trick. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737652599647-CH59UV8Q04XFEOTDE94O/IMG_5294.jpg Paoli Bookshelves With the addition of the under-shelf lighting, these bookshelves create a nice focal point in the space without overwhelming it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737652598490-37QJ7W4YD21ETHGJSA1N/IMG_5115.jpg Paoli Bookshelves Before picture (sort of); I didn’t remember to take a picture until I had already gotten started. http://www.greengatewoodworks.com/gladwyne-window-grids daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737653472002-NFY8KTFU9AFN66M8O0PV/IMG_4493+2.jpg Gladwyne Window Grids Sometimes little things can make a big difference. A long-time client of mine owns this circa 1830s home in Gladwyne, and she strives to maintain the character of the home. The original windows had been replaced by a previous owner with casement windows, which just didn’t look right. In lieu of replacing the windows again, she asked me to make grilles to give the appearance of traditional divided-lite, double-hung windows. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737653472002-NFY8KTFU9AFN66M8O0PV/IMG_4493+2.jpg Gladwyne Window Grids Sometimes little things can make a big difference. A long-time client of mine owns this circa 1830s home in Gladwyne, and she strives to maintain the character of the home. The original windows had been replaced by a previous owner with casement windows, which just didn’t look right. In lieu of replacing the windows again, she asked me to make grilles to give the appearance of traditional divided-lite, double-hung windows. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737653470146-26EXLM6RT5PSM7TNLXSK/IMG_4494+3.jpg Gladwyne Window Grids Although it was a challenging project that involved overlapping multiple thin layers of wood that are prone to breaking during the fabrication process, the finished product really makes an incredible difference in the home’s facade. . https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737653472004-C59FSKKV8ZL47O0XPNZ4/IMG_4528+3.jpg Gladwyne Window Grids I forgot to take a “before” picture, so I grabbed this screenshot from Google Street View where you can see how the windows looked to start. The interior of the home is as charming as the outside, and I’ve had the good fortune to work with this client on multiple projects, like this spalted maple mantle, floating shelves, built-in linen closet, and small bar cabinet. http://www.greengatewoodworks.com/penn-valley-office-builtins daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737667805113-6O10W99Q5CPB7GMS562R/IMG_9836.JPG Penn Valley Office Built-ins Green is my favorite color, and I like working in older houses, so I especially enjoyed creating these office built-ins for this Penn Valley home, built circa 1800. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737667805113-6O10W99Q5CPB7GMS562R/IMG_9836.JPG Penn Valley Office Built-ins Green is my favorite color, and I like working in older houses, so I especially enjoyed creating these office built-ins for this Penn Valley home, built circa 1800. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668054010-MK26HNSAJGZH7YLIV5YU/IMG_9837.JPG Penn Valley Office Built-ins Matching the original wall color, Sherwin Williams “Shade Grown” (SW6188), the built-ins feature beaded face frames, inset flat-panel doors and drawers, and the under-shelf lighting and wall sconces add to the cozy feel of the room. Pull-out shelves inside the center unit will give easy access to a concealed printer, and one of the drawers has two in-drawer outlets for charging iPads, phones, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668289997-JLEXW7F6Q85IXTBW7USH/IMG_6671.jpg Penn Valley Office Built-ins After I had finished, the clients sent me this photo of the decorated built-ins. Overall this was a fun project, and what pleased me most was what the client said to me when the job was completed: “It looks like it’s always been here.” http://www.greengatewoodworks.com/media-mudroom daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668985478-01SXEMYO8GWH47UC756B/IMG_9839.JPG Media Mudroom Planning for the future is important when designing a project. A previous client had moved and contacted me to create a mudroom area in their new home. They wanted to use a space that was an extension of the kitchen for the mudroom; however, their refrigerator is currently housed there. As part of a future renovation, the fridge will move elsewhere, freeing up space for a larger mudroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668985478-01SXEMYO8GWH47UC756B/IMG_9839.JPG Media Mudroom Planning for the future is important when designing a project. A previous client had moved and contacted me to create a mudroom area in their new home. They wanted to use a space that was an extension of the kitchen for the mudroom; however, their refrigerator is currently housed there. As part of a future renovation, the fridge will move elsewhere, freeing up space for a larger mudroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668985699-NEPMNDWIVCHE02EBP6O9/IMG_9840.JPG Media Mudroom In this current phase of the project, I removed the original cabinetry, swapped the radiator out for a shorter, lowboy unit, and then built these lockers with a black walnut benchtop, stopping just short of the fridge. When creating the benchtop for this project, I fabricated one large enough for the entire future space and cut it to length to accommodate the fridge. The remaining section of the benchtop slab will live in my shop until it’s time for Phase II, when I’ll join the two sections back together again. By taking that approach, I’ll be able to line all the wood grain up nicely, resulting in a more seamless finished product. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668986394-9ZDH9S5FUYLLRABU83YO/IMG_9841.JPG Media Mudroom These multi-tiered hooks swivel open and provide a lot of options for hanging storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668986660-VIXYR3WCREDUQGOT87O9/IMG_9842.JPG Media Mudroom The original cabinetry and radiator cover that I removed. http://www.greengatewoodworks.com/malvern-multiple-builtins daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737669835407-KE9JNVH7CMGN8C53Q3IL/IMG_9843.JPG Malvern Multiple Built-ins A repeat client contacted me after moving into a new house and was in need of storage solutions throughout her home. She has an affinity for built-ins, as her last several houses have had them, so I designed and built several different projects for her. The first one featured here is additional kitchen storage in what was once an empty alcove. The bottom features two large file drawers on the left and a storage area on right side of the cabinet. It’s topped by a black walnut countertop, which looks nice paired with the custom wainscot backsplash. The cabinet on top features overlay, divided-lite glass doors to match existing the kitchen cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737669835407-KE9JNVH7CMGN8C53Q3IL/IMG_9843.JPG Malvern Multiple Built-ins A repeat client contacted me after moving into a new house and was in need of storage solutions throughout her home. She has an affinity for built-ins, as her last several houses have had them, so I designed and built several different projects for her. The first one featured here is additional kitchen storage in what was once an empty alcove. The bottom features two large file drawers on the left and a storage area on right side of the cabinet. It’s topped by a black walnut countertop, which looks nice paired with the custom wainscot backsplash. The cabinet on top features overlay, divided-lite glass doors to match existing the kitchen cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737669835783-CKSOO94OD9DIRKFJI19V/IMG_9844.JPG Malvern Multiple Built-ins The file drawers have metal bars set into the drawer box to accommodate standard size hanging file folders. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737669836372-S7B54EAC2A38C04GEJ2D/IMG_9845.JPG Malvern Multiple Built-ins This family room wall , originally blank, was completely transformed with a pair of built-ins tied together with a new mantel and custom wainscoting which matches the kitchen built-in. New sconces I installed above the mantle will highlight some of the client’s artwork. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670141316-IO9OCBQW14H454M7PE6H/IMG_7351.jpg Malvern Multiple Built-ins Across from the large living room built-ins is this cabinet set into a nook to house their TV. The cabinets are a full 24” deep for plenty of storage, and a false back in the central section keeps the TV close to the front for easy viewing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670148111-B1ZA12PTJXC48QRMX5NN/IMG_7355+2.jpg Malvern Multiple Built-ins In a room adjacent to the living room is this set of bookshelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670142814-E0769SN0PUL18VO0YA43/IMG_7216+2.jpg Malvern Multiple Built-ins The final set of bookshelves is set in an upstairs bedroom. http://www.greengatewoodworks.com/malvern-mudroom daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670947642-210J9LC3JAEJE311DVUR/IMG_9851.JPG Malvern Mudroom This mudroom created a massive amount of storage for the client. The open cubbies below the black walnut benchtop provide ample room for shoes, etc., while the folding triple hooks mounted above on a matching black walnut board provide lots of options for hanging storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670947642-210J9LC3JAEJE311DVUR/IMG_9851.JPG Malvern Mudroom This mudroom created a massive amount of storage for the client. The open cubbies below the black walnut benchtop provide ample room for shoes, etc., while the folding triple hooks mounted above on a matching black walnut board provide lots of options for hanging storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670947949-1RDW3RDUYMP6Q7L2VPIO/IMG_9852.JPG Malvern Mudroom The overhead enclosed cabinets and open cubbies on the right, which are sized to fit baskets the client picked out, create a great spot for storing smaller items and seasonal things (gloves, hats, etc.) https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670948623-X39VVZY2EVXFCV3MXJY0/IMG_9853.JPG Malvern Mudroom The tall cabinet on the far left boasts two pull out shelves in the bottom section and even more folding hooks in the upper portion. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670949344-VAZ3XSGFOFE7GOFP4OLH/IMG_9854.JPG Malvern Mudroom The custom wainscoting in the main hanging area adds a nice subtle detail to stand out from the crowd. This project was painted using Fine Paints of Europe Eco Satin in Farrow & Ball’s Blue Grey #91. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670944180-8S144NR00XEWKWCX89MF/IMG_9846.JPG Malvern Mudroom This cabinet sits directly across from the lockers and provides even more storage space in an existing alcove. On top of the black walnut countertop sits a stand-alone mail organizer, also made from black walnut. The difference in color is due to how the boards are treated at the mill, which I’ll explain in the final picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670944599-4UQI5B94XLKRSVJNLCTL/IMG_9847.JPG Malvern Mudroom Inside the cabinet, there’s a drawer that houses a container for dog food with additional storage behind it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670945098-LN3VF0I68X0CDWU3JCVY/IMG_9848+2.JPG Malvern Mudroom The small door behind the dog food container allows access to the interior of the drawer where small items can be stored. Cut from the original drawer top, the door grain matches its surroundings seamlessly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670945994-1ANQS0X48O0XAO2Y6BD5/IMG_9849+2.JPG Malvern Mudroom The difference in the color of the countertop and the mail organizer is because the countertop walnut is steamed, and the mail holder walnut is not. When walnut is steamed, it results in a more uniform color between the typically darker heartwood and much lighter sapwood. While both steamed and unsteamed walnut look great, steamed walnut is nice to use when creating a countertop from multiple boards because it’s more consistent in color. Walnut that hasn’t been steamed has bolder, more dramatic colors, and I had a couple pieces I was saving because they were so beautiful, so I decided to use them to fabricate the mail organizer. The boards weren’t quite wide enough for what I needed, so I resawed them and bookmatched the pieces. This aligns and mirrors the grain, as shown above. http://www.greengatewoodworks.com/merion-station-builtins daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737672816815-L181MX2G81MYJ3PJ42UO/IMG_7563.jpg Merion Station Built-ins For this project, the client wanted to convert an existing alcove into a set of built-ins that would conceal their TV when not in use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737672816815-L181MX2G81MYJ3PJ42UO/IMG_7563.jpg Merion Station Built-ins For this project, the client wanted to convert an existing alcove into a set of built-ins that would conceal their TV when not in use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737672822648-WKNJM117CWSBMAO3MROD/IMG_7715.jpg Merion Station Built-ins The finished project features inset flat-panel doors and a black walnut countertop. Set into the countertop and the upper cubbies are a pair of tracks the doors ride in. When opened, they stack up over the outer open shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737672816589-78IN7P9H79LYEAHXLYGN/IMG_7714.jpg Merion Station Built-ins When closed, the doors conceal the TV and give the project a unique look. http://www.greengatewoodworks.com/merion-station-library-builtins daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737673699227-8OG0RQLM1XF8KU2JR7HA/IMG_9856.JPG Merion Station Library Built-ins “Help us create our library!” was the request from this client, who was looking to redo their third floor office space to give it a cozy, library feel. The built-ins that replaced the original filing cabinets (before pic at end) have raised-panel, inset doors to match other doors in the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737673699227-8OG0RQLM1XF8KU2JR7HA/IMG_9856.JPG Merion Station Library Built-ins “Help us create our library!” was the request from this client, who was looking to redo their third floor office space to give it a cozy, library feel. The built-ins that replaced the original filing cabinets (before pic at end) have raised-panel, inset doors to match other doors in the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737673699421-NJO8MZ8YOZ6XLR2TL4M0/IMG_9857.JPG Merion Station Library Built-ins The large drawer under the window seat is the perfect place to stash a blanket for curling up with a good book, and under-shelf lighting adds to the cozy vibes. I certainly got a workout hustling up and down the stairs all day, but it was worth it in the end. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770854407109-W3BCABWJ4Q9TFLRKD7S1/Screenshot+2026-02-11+at+3.05.30%E2%80%AFPM.png Merion Station Library Built-ins After my work was completed, the client had wallpaper installed along the back of the bookshelves and was kind enough to send me this finish picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737673700064-LZVS0IVBMVHAS7WTAGUA/IMG_9858.JPG Merion Station Library Built-ins “Before” pic http://www.greengatewoodworks.com/chester-springs-window-seat daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675131175-H2P8Z2A9FCB8AMCO1SY2/IMG_8622.jpg Chester Springs Window Seat This client needed additional storage in their kitchen, and wanted to utilize the dead space under their existing window seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675131175-H2P8Z2A9FCB8AMCO1SY2/IMG_8622.jpg Chester Springs Window Seat This client needed additional storage in their kitchen, and wanted to utilize the dead space under their existing window seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675230704-MKETCR3509VDFMXG0QQU/IMG_8717+2.jpg Chester Springs Window Seat I removed the existing drywall and studs, leaving a temporary prop in place to keep the window seat top from sagging. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675131537-AD0Q4QMSKUQIU5UBVA09/IMG_8720.jpg Chester Springs Window Seat I built and finished this drawer base in my shop, then slid it into place under the window seat top and secured it to the framing inside. Now, the window seat remains, but provides plenty of storage in the large drawers below. http://www.greengatewoodworks.com/lego-display-bookcase daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675963546-0YHDZX8BIKFNME2KCCVP/IMG_9859.JPG Lego display bookcase This client was looking for something where her kids could display their built LEGOs. If you know me, green and LEGOs are two of my favorites, so this was a fun project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675963546-0YHDZX8BIKFNME2KCCVP/IMG_9859.JPG Lego display bookcase This client was looking for something where her kids could display their built LEGOs. If you know me, green and LEGOs are two of my favorites, so this was a fun project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675963893-4S5NH2WBRKO6DT6F1AS1/IMG_9860.JPG Lego display bookcase I had barely installed it before the kids started loading it up with their LEGO creations. http://www.greengatewoodworks.com/spalted-maple-desk daily 0.75 2025-01-25 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734595048-I9XAFL0P8C401WN49XSZ/IMG_7220+3.jpg Spalted Maple Desk This project came to me from a repeat client who loves spalted maple. She asked me to keep an eye out for a large piece that we could turn into a desktop, and I came across this slab with absolutely beautiful coloring at Groff & Groff Lumber https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734595048-I9XAFL0P8C401WN49XSZ/IMG_7220+3.jpg Spalted Maple Desk This project came to me from a repeat client who loves spalted maple. She asked me to keep an eye out for a large piece that we could turn into a desktop, and I came across this slab with absolutely beautiful coloring at Groff & Groff Lumber https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734595015-IEAQCNU8FTEAVRLUSVGO/IMG_8826+2.jpg Spalted Maple Desk In order to find the best layout, I made up a template from plywood strips showing the finished size of the desk. I moved it around until I found the position that had a nice balance of color and worked well with the thickness of the slab which was variable on the bottom side. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734607281-PNZUJ97W15P2EQSMDV3Z/IMG_8858.jpg Spalted Maple Desk Once I had cut the slab to size, there were a few areas that needed reinforcing with epoxy, specifically the back edge of the desk where the slab was a little thin. I attached temporary plywood pieces to the areas that needed to be reinforced, then did several epoxy pours until low areas were filled in fully. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734608127-IG992UTW6BUAB432YA3V/IMG_8997a.jpg Spalted Maple Desk After the epoxy had cured for a few days, I sanded the entire slab down, finished it with a wiping varnish to match other spalted pieces in this client’s home, and then I attached it to the motorized desk base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734621369-M59NTUTQH2PVM1C5QA3T/IMG_9143.jpg Spalted Maple Desk The finished product delivered and installed at the client’s home. This is a standing desk base from Uplift and raises and lowers at the touch of a button to transition from sitting height to a standing desk. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734621938-LNXTSP4LMMBZWOHT2WY0/IMG_9148.jpg Spalted Maple Desk Another shot of the finished project. http://www.greengatewoodworks.com/emmett-build-pics daily 0.75 2025-01-26 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838297133-4S0ODW1B6AC6ZZBW8M4K/IMG_7079.jpeg Emmett Build Pics This is the more in-depth record of the build of Emmett, mostly written for my own records, but I figured some people might be interested in reading through it. These aren’t all the pictures, nor are they in the exact order I did things. I tend to jump around working on various aspects of a project like this where there are many different issues to be sorted out based on whatever solutions I’ve come up with at that moment. That being said, I’ve put the pictures in what I consider to be a somewhat logical order. After coming up with the initial idea, I took detailed measurements of all aspects of a standard lego figure with my digital calipers, then set up a spreadsheet that would scale them up according to the final size I wanted the piece to be. I ran several different options at the same time until I found the numbers that I felt made the most sense, primarily based on the depth of the torso cabinet section as that was the main storage area, which was based on some plastic bins we had found which went with the figure for storing lego bricks. This was one of the first projects I did in my new shop after renovations. The actual construction on this (not the time I spent figuring out dimensions, planning, etc) started on or about Feb 26th, 2022 and ended on April 25th, most of the work being done in my spare time between jobs, on weekends, and in the evening. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838297133-4S0ODW1B6AC6ZZBW8M4K/IMG_7079.jpeg Emmett Build Pics This is the more in-depth record of the build of Emmett, mostly written for my own records, but I figured some people might be interested in reading through it. These aren’t all the pictures, nor are they in the exact order I did things. I tend to jump around working on various aspects of a project like this where there are many different issues to be sorted out based on whatever solutions I’ve come up with at that moment. That being said, I’ve put the pictures in what I consider to be a somewhat logical order. After coming up with the initial idea, I took detailed measurements of all aspects of a standard lego figure with my digital calipers, then set up a spreadsheet that would scale them up according to the final size I wanted the piece to be. I ran several different options at the same time until I found the numbers that I felt made the most sense, primarily based on the depth of the torso cabinet section as that was the main storage area, which was based on some plastic bins we had found which went with the figure for storing lego bricks. This was one of the first projects I did in my new shop after renovations. The actual construction on this (not the time I spent figuring out dimensions, planning, etc) started on or about Feb 26th, 2022 and ended on April 25th, most of the work being done in my spare time between jobs, on weekends, and in the evening. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838301015-2IR9RMQYI9ZUFJOKO0SD/IMG_8929.jpeg Emmett Build Pics The first section I built was the torso cabinet because it seemed the easiest place to start since it’s fairly straight forward. Typically I set fixed shelves in my cabinets into dadoes cut into the sides and back of the case, but with this one the angles made cutting those dadoes difficult, or at least enough of a concern that I’d spend too much time fixing mistakes, so I cut the shelves to size and glued and tacked them from the outside. Since they won’t be holding much weight, this was an acceptable compromise from my normal techniques. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838301622-98NTS0LDJEPAOGHLP5DQ/IMG_8933.jpeg Emmett Build Pics For the leg cabinet, the bulk of it is also a straight forward cabinet case, just with the outer side run long. I found the center point of the radius for the upper section of the leg and marked the curve so it sat above the flat top of the leg cabinet, this will get trimmed off later to that curved line. The upper “waist” portion of the legs will be a torsion box added later, and the outer face of it will follow that same curve and sit directly on top of the leg cases, giving the legs the appearance they rotate even though they are fixed in place. For the door front, I used a single piece of 3/4” cabinet plywood, built a small box from primed pine for the toe, then cut two plywood arcs for the upper curved portion of the leg. In between those two arcs, I filled in the space with primed pine strips cut with angles on the long edges so that they would follow that arc approximately. Those primed pine pieces are later sanded down to match the curve of the plywood arc pieces, although that won’t show up in the pictures for a while. I also added thin strips of primed pine to cover up any exposed plywood edges, they can be seen here (the white strip between the door and the main cabinet case), and can be see in pictures moving forward on the torso cabinet. I added them to the torso cabinet face, the front of the shelves, and to the edges of the torso doors as seen in later photos. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838279472-GYV61SZU09SLO57XACUC/IMG_3699.jpeg Emmett Build Pics I don’t have any pictures of it, but the center portion of the legs (between the leg cases and the torso cabinet) is just a plywood torsion box. At this point I hadn’t cut off the upper portion of the leg cases, that’s taken care of later, for now I was just testing the overall fit to see how things looked, but because of that the legs are spaced farther apart than they will be at the end. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838306352-0I8CFHVZJEZ1NB0TF8SM/IMG_9043.jpeg Emmett Build Pics For the arms, I had to create a couple tubes built up out of long primed pine rips with angled sides. This is for the lower forearm portion of the figure as they are straight tubes, and this was enough to do both forearms. I used biscuits on each piece to join them up and to keep the pieces from slipping during the glue up process. Once I got them loosely assembled I used tie down straps to tighten up the joints and then left it overnight while the glue dried. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838306352-ILS4785UNMZ8MWNL4W0F/IMG_9045.jpeg Emmett Build Pics This is looking down at that forearm tube from the top to show the angled pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838325697-TBO3E4MN39EX8O7AVK1H/IMG_9087.jpeg Emmett Build Pics The upper arms were more difficult because they were tapered tubes, figuring that out took a bit more math, shown in later photos of my notes. I used this tapering sled from another project to make the pieces. First step if clamping a piece of primed pine in place, then running it through the angle saw blade. In this photo, i’ve already done done one side of the rips. As I recall I had to do one rip on each piece, then adjust the sled to do the other rip so it was at the proper angle. If i’d used the same sled and just rotated the piece, I’d have ended up with a straight piece at the end instead of a tapered one. Don’t seem to have any pictures of the first pass, but that was probably done just against the fence on a table saw with no sled, I think the sled was only used to do this second pass which created the taper. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838326661-X9J8UBD6URIQCE055UGP/IMG_9088.jpeg Emmett Build Pics This is the final tapered piece, it’s upside down (you’re seeing the inside face of it) because my saw blade leans to the right. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838329520-JB46QAY8GD3II6TB45PR/IMG_9089.jpeg Emmett Build Pics This is the narrow end, the bottom of the upper portion of the arm, essentially at the elbow. As I recall, this dimension was the same as the forearm tube pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838330565-BUKRLZHJI206DWR5Y092/IMG_9090.jpeg Emmett Build Pics This is the wide end, the top of the arm. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838334376-7E1U8V75GMBKY03SS5L1/IMG_9096.jpeg Emmett Build Pics i assembled the upper arms the same way I did the forearms, with biscuits, glue, and tie down straps. After the glue had cured overnight, I marked out the angle needed to create the elbow joint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838335004-BAWVKN8D00EE2Y6BGGR9/IMG_9098.jpeg Emmett Build Pics In order to get a straight cut on the tapered tube, I made up a tapered sled for it to right on while going through the band saw. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838339376-4QQ2OJXLJQ0YCN7VZMF3/IMG_9100.jpeg Emmett Build Pics Since the cut was also on an angle, I just took my time and free-handed it instead of riding along a fence. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838339952-DY7GSFJGF024YGQF1MUR/IMG_9103.jpeg Emmett Build Pics The forearm portion had to be cut on the bandsaw to have a corresponding angle on the top end so it would align properly with the upper arm portion. I forget exactly how I marked the forearm for cutting, probably held it up at the correct angle and scribed it but I’m writing this 3 years after i did it, so I don’t remember precisely. For connecting it to the upper portion, I believe I also use a couple biscuits in here and then glued it up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838349265-XIHGP7Q6ZIWWSUHIFTLB/IMG_9111.jpeg Emmett Build Pics Next up was trimming off the inner edge of the upper arm to create a flat surface where the arm would meet up with the torso cabinet. I’m not sure why this has a tie strap on it at this point, but I think at this point I had glued it but only snuck a couple trim screws in through the outside of the elbow joint. There were no screws on the inside (top edge) of the elbow joint, they were added later, so I think I used the strap to pull that glue joint tightly closed while it was setting up and until I could sneak a couple screws in later through the inside of the tube once it was trimmed off. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838350103-NPWXVIE94UKX20AYSLXV/IMG_9112.jpeg Emmett Build Pics For this one I did use a fence while going through the bandsaw, but I didn’t create a sled to hold it in place, I just freehanded it (sort of) again and took my time. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838354494-EUO2Q9M8PL5MXQB28033/IMG_9114.jpeg Emmett Build Pics With the portion trimmed off where it would meet the torso cabinet, the interior of the arm was more accessible and I believe I snuck a couple trim screws in from the inside to secure the two sections together. Again, I don’t remember exactly, but I sometimes use small T-10 trim head screws from GRK on my projects, and it was probably those I used here. After this I built up the top portion of the shoulder using layers of primed pine on edge, cut roughly into semi circles and stepped much like i did with the hair and head pieces. Then I filled the remaining opening (where the arm meets the torso) with a plywood piece in order to make the arm connection, which is shown later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838311508-44GS6DTTF6649C6CIRUR/IMG_9061.jpeg Emmett Build Pics I’m going to jump to working on the hands now and get back to the arms later. I ordered this large 3” diameter maple dowel from amazon for the wrist portion of the figure. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838316999-JJI3JMHN2I1R9TIWDUKX/IMG_9081.jpeg Emmett Build Pics The hands are essentially tubes that are trimmed off with a curved bottom, so I decided to build them up out of multiple rings of primed pine. I first cut square blanks, then trimmed off the corners into an octagonal shape. Then I built this jig to hold the octagons in place while I drilled out the center with a hole saw bit. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838322121-VVJLV5K5VDU4DFQJPR1O/IMG_9082.jpeg Emmett Build Pics This is one of the finished pieces of the hands. Multiple layers were glued together to build up blanks for the hands. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838322202-KFTBGTG4DUDVK9XBCVDH/IMG_9084.jpeg Emmett Build Pics From these pictures it looks like I used 9 layers of 3/4” thick primed pine for each hand, then I cut the openings on the table saw or bandsaw. After that I rough cut the bottom curvature using a bandsaw, then a lot of sanding to smooth everything inside and out, again using my oscillating spindle sander and upright belt sander. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838342824-5KRHVMBTUQ135U3PWP33/IMG_9104.jpeg Emmett Build Pics To attach the hands to the wrists, I drilled out a section in the back of the hands to fit the wrist dowels. I believe i did this on my drill press with a hole saw blade without any centering bit on it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838343764-PW4C5J5CZ4YQ5Q5X7U95/IMG_9106.jpeg Emmett Build Pics The hands are angled in comparison to the wrists, so I cut the ends of the dowel to a 15º angle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838345599-LAG65KOXJDHN38TUQ4L9/IMG_9108.jpeg Emmett Build Pics The hands were attached to the wrist using glue, a couple brads, and a couple of those trim head screws as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838283994-KWDJC1ZAXX6DVD3J5GXV/IMG_3794.jpeg Emmett Build Pics The wrists also have a groove cut in them to accommodate a pair of set screws in each arm that hold the wrists in place while allowing them to rotate. These set screws were set into threaded inserts in the forearms. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838287765-4CELBOJKSXSKWAUJZ7OY/IMG_3796.jpeg Emmett Build Pics Doing a test fit of the arms to see how things look. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838310878-EOSJIEYA1BAB2DV9IKU1/IMG_9060.jpeg Emmett Build Pics At this point I had cut the curve in the top of the leg cabinet outer faces, and then trimmed the side piece of the “waist” torsion box to follow that curve, thus creating the look you see here of the typical upper connecting piece of a lego figure’s legs. The outer sides of the torsion box are double up with 2 pieces of primed pine, the outermost one gets cut to match the curve, the inner one remains intact so it sits firmly on top of the leg cabinet. I also added a central curved piece between the legs to resemble a real lego figure, it was a plywood disc with a flat edge that abutted the bottom of the torsion box I believe. If I remember correctly, this was attached to that bottom of the torsion box by some trim head screws run down into that center curved piece (I believe the torsion box was open on top, with some central ribs, and the torso cabinet was screwed down onto them. Not 100% on that, I’d have to check my notes to see if there’s more info). Judging by the screw holes in the front of that torsion box, I think it had no top and a bottom only in the center where that leg divider was attached. NOTE: I confirmed this later through other pictures, the torsion box was open on top and bottom except for a central bottom piece where the leg divider attached. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838316612-25M6OKVNO2OGGQZZMMK4/IMG_9076.jpeg Emmett Build Pics Jumping to the head now. This is the main central portion of the head, without the curved top and bottom sections. I built this using arcs like the one you see here cut from primed pine. I rough cut them out of primed boards on the bandsaw, then I believe I sanded them to the line using an oscillating spindle sander and an uprgitih belt sander. This could be done with a bearing bit on the router table, but given the change in grain over the course of this arc that would risk tear out and possibly breaking the piece, and I don’t remember that happening so I don’t believe I used that technique. The arcs were cut longer than needed (more than half the circumference of the head), and then I built a sled they were clamped into and run through the table saw to get that half-diameter length and parallel end cuts. After that I assembled them by staggering the joints between each layer, but I made sure that no joints would land inside the area where the door would be in Emmett’s face. I had marked that location on the first arcs and then kept track of it as I was moving upward. I don’t think the pieces here have been assembled, I think this picture is just a dry fit, however I believe I built up the center section like this and sanded the interior on the oscillating spindle sander, then attached the entire thing to the base and then put the top on . If I had built it up layer by layer on the base piece, I wouldn’t have been able to sand the interior easily, it would’ve been a nightmare to get smooth and I don’t remember that being an issue. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838354242-G8CDUAEN1CGTFNRYOLMR/IMG_9148.jpeg Emmett Build Pics Midway up the head I trimmed the interior of one of the rings to accommodate a shelf that would divide the head into two sections. The thicken portion on the right side is where the door will be in the face of the figure. If you zoom in on the lower portion of this photo, you’ll see the staggered joints between each half section of the arcs that I mentioned in the previous photo. Also by this point I’ve attached the bottom of the head, which was built up of wider cut rings of primed material at the bottom with a plywood disc inserted for the bottom “floor” of the head. I didn’t have primed material wide enough to make full circles, but I still needed to carve away at them and sand them into a smooth curve on the exterior, which is why I made those ring much wider than the ones that make up the main central portion of the head. I didn’t use plywood discs because sanding and carving them away would leave raggedy edges and possible voids, which would lead to more repair work later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838357918-8SDONVY5E0AO0T4S3TKI/IMG_9149.jpeg Emmett Build Pics After the shelf was set in place, I continued building up more rings until I got to the upper portion of the head which was made from solid circles cut from primed pine just the bottom portion of the head. I also used a series of smaller circles for the neck. Note the area marked “No Glue”, this is the top of the door, and I was going to be attaching the upper wood circles now to make the top of the head. Leaving glue off here gave me a clean break for the door opening, and by doing the same “no glue” section at the bottom, all I had to do to get the door cut out was to cut the vertical openings on either side. I could have glued everything in place and then cut it out, but this way I could get a nice straight line at top and bottom with no risk of waviness from doing it by hand. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838359780-9BA6NELD5G7ANDG2AZFY/IMG_9154.jpeg Emmett Build Pics Here’s the head loosely set on the torso, again just to see how things looked. If you zoom in on this photo, you’ll see a vertical line on the left side which is where I’ll cut for the door opening. At the top and bottom of that line, you can see, closer to the middle of the head, the gaps where there is no glue that I mentioned previously. Obviously by this point I’ve attached the upper portion of the head, which was made in the same fashion as the bottom section. Wider rings of primed material that stepped in as I went up, and were later carved/sanded away into a smooth exterior arc, and then the center of the head is capped with a plywood disc set into that uppermost ring (visible in the next photo). Since this figure will have hair, that top plywood disc will be covered in the finished product. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838360720-JL23L2CYD339TSWMTMZP/IMG_9158.jpeg Emmett Build Pics The rings of the head had a number of voids, cuts, etc on the exterior after sanding, so I used drydex compound to fill them, which I applied by just slathering it on with my hands. Once dry I sanded it smooth again. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838364545-7EH3NAZK866KG4GS4D2J/IMG_9182.jpeg Emmett Build Pics Next up was cutting the door open. I only had one shot to get this right, so I took my time and used an oscillating cutter. This cutter also ensured that the gaps in the door would be pretty minimal. Again, I was only cutting out the vertical sides of the door since the top and bottom were already set with the unglued gaps I mentioned earlier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838364968-ZEDZEPRSTM88Q22MD88I/IMG_9184.jpeg Emmett Build Pics The head with the door cut out and removed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838370468-FTUKDPKG6PLMOKTWJ9A2/IMG_9187.jpeg Emmett Build Pics Not sure if I had put the hinges on, or if this is just with the door wedged in place, but this is what it looked like when opened. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838375903-R0715SZKLLAJK5HMSLUY/IMG_9239.jpeg Emmett Build Pics Next up was building the hair, which I decided to make like it was sitting on top of the head like it does with a real lego figure. First step was to make a series of rings that were wide enough to fi over the main body of the head. These rings, and all of the hair I believe, were made from plywood arcs and discs because there were no primed boards wide enough to do it in one shot. As much as I would prefer carving and sanding on real wood as opposed to plywood, there was no other option that would have made sense. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838370678-ILBRCB1762MEDGGLREUG/IMG_9238.jpeg Emmett Build Pics After that I added plywood discs on top to build up the bulk of the hair, with the layers stepping in as they got closer to the top. They are stepped in so I don’t have to remove an excessive amount of material later when I’m shaping the hair. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838376884-L5KRM8CVGAAU4MCS6NQ5/IMG_9246.jpeg Emmett Build Pics Next I trimmed away the inner edge of the hair blank so it would not cover up the door opening in the face. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838380514-OWFAPCX5R08RGSIOKQOP/IMG_9247.jpeg Emmett Build Pics This is the hair blank sitting on top of the head. By this point I’ve installed some small hinges for the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838381720-34ZMB3I3RWOX2MWNROHJ/IMG_9251.jpeg Emmett Build Pics Using a series of measurements taken from the actual figure, I roughly sketched the shape of the hair and tried to eyeball how the top of the hair would curve over. I also made a line around where the hair was at its thickest point based on the actual lego figure, so I could know where to start carving away the upper layers into a smooth curve. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838384495-YAQR2MQNB2FZENIHQITA/IMG_9253.jpeg Emmett Build Pics I did the same thing on the other side. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838387216-RH0EKJ6IVV7X6U26CHWW/IMG_9271.jpeg Emmett Build Pics Back in the shop I cut the hair roughly to size using a jigsaw. I also made up this base where I could rotate the piece while I worked on it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838409340-ZLBAS0GTBR9APY6D0YFR/IMG_9372.jpeg Emmett Build Pics I spent a while spinning the hair and head to see where things needed to be trimmed. I would mark areas with a sharpie, then sand/grind them down and recheck how things looked. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838415152-6QWHCWDEWTBKEFI3Y0YB/IMG_9458.jpeg Emmett Build Pics Instead of trying to carve the cowlick out of the main body of the hair, I made it as an extra piece. Not sure what I made this from, I had some rough 8/4 pine stock in the shop back then, so it may have been from a chunk of that because this doesn’t appear to be built-up from smaller pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838419861-BCSLYSS5I3ZF9K50RY6U/IMG_9461.jpeg Emmett Build Pics I bought a grinder attached, probably from amazon, and used it carve away the inside of the cowlick. I sanded it first on the spindle sander to get it to the correct arc, but it also needed to have some material removed along the long center line of the underside so that it would better conform to the curvature of the head, which is what I used this grinder attachment to do. I believe I also used that same attachment to grind away parts of the hair while I was shaping it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838415150-X5C49XB42VXX794THM16/IMG_9460.jpeg Emmett Build Pics This is the final bottom edge of the cowlick. Doesn’t have to be perfect as it was going to be glued in place and tacked, but I still wanted to get it pretty close so the glue connection was solid. Here you can also see where I had carved away the inside along the centerline so that it didn’t wobble when placed on the head and the outer edges sat as close to the surface of the head as possible when attached. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838420544-Y08986PWI82XBV9J4N2A/IMG_9462.jpeg Emmett Build Pics I also decided to draw on the face using sharpies I had in the shop. This wasn’t necessary at this point since it was going to be painted over anyway, but I wanted to see how it would look so again, I took some detailed measurements of the face and then transferred it to the full size head. This was when I felt like it was really starting to look like something. Also this turned out to be useful later as the sharpie showed through the yellow paint, and it was easy to retrace everything without having to make a mess of the paint with layout lines, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838426705-0FEZU85MOMVF2KSB4HEA/IMG_9465.jpeg Emmett Build Pics With the hair on I continued to sand and refine it, then I used the grinder attachment to carve the lines into the head from the original figure. This was just done freehand after eyeballing it and sketching some paths with a sharpie. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838427064-5B6058ET2VRURZ1I3VSZ/IMG_9466.jpeg Emmett Build Pics Looking at the backside of the head. I must’ve attached the cowlick shortly before taking this picture, because you can see the glue is still wet where it meets the head. I believe I tacked it in place and then added a few small trim head screws to secure it, you can see where I used the drydex to fill the holes on the cowlick. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838388238-IJQGCXS35XOB0K2Y4ASJ/IMG_9301.jpeg Emmett Build Pics Jumping back to the arms. I made the shoulder portion of the arms from a bunch of half circles cut from pined pine which I then sanded to a smooth curve for the outer edge. On the inside of the arm, I filled it in with a solid piece of 3/4” cabinet ply and then cut out a large keyhole slot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838392853-ZUD6P43XCC9VSENFGHVY/IMG_9302.jpeg Emmett Build Pics I wanted the arms to be able to rotate, so I came up with this keyhole slot and shoulder mount made from wooden circles joined together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838392913-TVEUMA77WLRGI449Y813/IMG_9306.jpeg Emmett Build Pics The joint drops into that keyhole slot and then slides up into the arm, allowing it to be securely hung while still being able to rotate. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838398107-4TLXCX4UCSB180598XPS/IMG_9309.jpeg Emmett Build Pics After test fitting the arms, I realized they wanted to fall in at an angle because that backer plywood circle on the shoulder mount was too small, so I made a larger ring that matched the outer diameter of the arm where it meets the torso. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838398438-ONT5G2AB2L8R4LJ91NPF/IMG_9311.jpeg Emmett Build Pics A test fit of the arm. Also, by this point, I’ve obviously sanded down the arm tubes, this was done using a standing belt sander and a disc sander, and probably some hand held sanders as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838403518-Q6Y1VLRIPBJX7VNU576K/IMG_9314.jpeg Emmett Build Pics Test fit of the body so far with both arms attached. At this point the arms only hang straight down. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838403896-DCXDSCOYDRF9HSV15WJ1/IMG_9319.jpeg Emmett Build Pics I wanted the arms to be positionable, so I embedded magnets into the outer ring on the torso side of the joint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838408968-BA0867DFP0EC3N8M1YMM/IMG_9320.jpeg Emmett Build Pics Magnets were also set into the arm at corresponding spacing. The arms were fairly heavy, and due to the leverage of them, the arms wouldn’t stay in each and every possible position, but they would stay somewhat forward which I was happy with. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838432363-GXSD7XPD11ANQ7PABP17/IMG_9480.jpeg Emmett Build Pics Now that the main portions of everything are in good shape, I started painting everything. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838432458-3HMKPNB9FOHX8OVQ208L/IMG_9481.jpeg Emmett Build Pics Some items like the arms and hands were hung from the ceiling for painting so I could get all sides in one shot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838437876-9ICK7EU948RL6O67CTIB/IMG_9487.jpeg Emmett Build Pics For the hair I recycled the shaping mount to be used as a painting mount. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838438367-URH51X7HU2TW2N2AKZNV/IMG_9498.jpeg Emmett Build Pics I attached the head to the body with glue and a few screws from underneath that went up into the neck. The hair is glued in place and secured with a few brad nails in the back. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838443131-BAD7EKH9Q58HA0LICGAM/IMG_9503.jpeg Emmett Build Pics Now it was time to add the details of the figure. first step was to layout for the reflective strips on Emmett’s vest and then tape them off and cover over everything else I didn’t want to end up silver. I used a reflective spray paint that I’m pretty sure came from Home Depot, most likely a Rustoleum or Krylon product. One note: I should have taped off the portion in the middle of the upper horizontal stripe so that it didn’t go all the way across. It should have stopped where the black edge details of Emmett’s vest come down. Since I ran it straight across, I had to paint the some of the blue portion of Emmett’s shirt overtop of that silver paint, and it always came through a little bit more than I’d liked, never quite got the blue color to be super consistent. Not a major issue in the finished product, but if I were to do it again I would make sure I only painted over the silver paint with black paint which had no issues. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838443519-4O290E9IDX4MNBXBR97Q/IMG_9504.jpeg Emmett Build Pics Here it is after spraying on several coats. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838448317-XBP8V4WWRAECF1CFAS7K/IMG_9506.jpeg Emmett Build Pics And with the tape removed. I don’t think I mentioned it before, but the doors for the torso cabinet were cut to follow the details on the original lego figure, that will be more obvious in the next steps, but it’s why the doors are unequal and angled at the top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838448438-YE6Y8F9VXKXFHZP69N5F/IMG_9508.jpeg Emmett Build Pics Next up I added the face back on using a sharpie, and added the main outlines on the details. Here you can see how the doors follow the angle of the details on Emmett’s vest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838452067-3VU3P8CQ52IVH3TQ4J2Q/IMG_9509.jpeg Emmett Build Pics I did the outlines in sharpie because it’s easier to get a straight line, but then I painted over them with black paint using a narrow artist’s brush. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838453667-30A6CHVHMSFIV1MTXSVD/IMG_9510.jpeg Emmett Build Pics Here all the detail outlines have been painted overtop of the silver reflective stripes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838457228-H5ABA2GV99JP4TRLESL0/IMG_9511.jpeg Emmett Build Pics Next step was to fill in color as needed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838461841-EE4YAGDQVN0GXNTO6JYZ/IMG_9532.jpeg Emmett Build Pics One last detail to add was Emmett’s name tag that is on his leg. I made a paper version printed to scale of what I wanted to do, then using a razor blade I cut out the design so I could easily follow it with a sharpie. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838462755-TP10UOII07K5Y6D5SGCV/IMG_9535.jpeg Emmett Build Pics Using a sharpie again to make the outlines, I also marked where portions needed to filled in solid black. Then I taped it off and added that silver reflective stripe. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838466680-NIFH0HKQFI60O8R4PAPP/IMG_9537.jpeg Emmett Build Pics After painting the black portions as needed, I filled in the remaining areas with a light grey paint I mixed in the shop (no records of amounts, etc, I just eyeballed it). This took a bunch of coats until the light grey areas looked good without any orange showing through. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838292037-TXIYHYX152H892KHK03T/IMG_3894.jpeg Emmett Build Pics The completed project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838296215-HXSEPNOJ8D72VRODB6L6/IMG_3895.jpeg Emmett Build Pics With the doors open. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838458221-2R6FY0EPXWWLSO5Y2MWS/IMG_9515.jpeg Emmett Build Pics I didn’t mention this earlier, but I also added details on the back, including large circular indentations to mimic the look of a real lego figure. I made them using a handheld trim router and just took my time to make sure there were no mistakes. Tricky part was at the top of the legs where the cabinet top curves in. I believe I made that section by layering up primed pine again to create the transition from the plywood back of the case to the plywood top of the case. After it was fully sanded and curved, I used the trim router to create these indentations and just carefully followed the curve at the top of the legs. I don’t recall sanding any curved sections inside the cabinet case, so that transition piece was probably just set in on an angle and then I curved only the outer face of it. NOTE: I looked back and found in another picture (not on here) where you can clearly see the inside of the leg cabinet. The top goes back, then angles down at approx 45º to where it meets the back piece of the cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838467032-H9WQN14S8GAAMA9PW4RL/IMG_9557.jpeg Emmett Build Pics The next few pages are a few of my notes, by no means all of them. i only took these photos because the kindergarten teacher (whose class I made this for) asked to be able to show some of the work that went into this project when displaying it at the school. This page is about how the head is constructed. Originally I had intended to make the lower portion of the head more spacious, but that required compound curves and eventually I figured it was more trouble than it was worth, which is why I used the solid wood circles for the lower and uppermost portions of the head. This also gave a nice flat bottom to the lower shelf when opening the door on the face, instead of having a drop down inside the head. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838471526-PHMO47HHOOZA9RNUWKEV/IMG_9558.jpeg Emmett Build Pics This is the original sketch I made when I came up with the project, a general idea of how the main body could open up for storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838471461-J03RZVSI3TAEVY5X17K1/IMG_9559.jpeg Emmett Build Pics This page has to do with the angles required to make the arm sections. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838475298-LLTV9YLIOPVOQRM0JDHV/IMG_9560.jpeg Emmett Build Pics This is detailing the wrist/hand setup and the set screws embedded in the arms. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838475713-JCYZ5JYH7F37BK7T9R0U/IMG_9561.jpeg Emmett Build Pics More detailed notes about the hands, angles relating to the wrist, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838480778-1GFR59MFBHIKT7CCJP2O/IMG_9598.jpeg Emmett Build Pics After Emmet was finished I had to transport him to the school, so I wrapped him in painter’s plastic, then covered him with large contractor trash bags. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838488636-QMNIKHUB56Q6PIIMS7CZ/IMG_9774.jpeg Emmett Build Pics Then I wrapped the whole thing in a bunch of canvas dropcloths for more protection. By this point I had also obviously painted the base black. Also I had trimmed the bottom of the doors off slightly so that they wouldn’t scrape on the base when opened. Not sure at what point I did that, but judging by some pictures I have of the back of the finished project, the leg cases are sitting directly on top of that black base, no spacers at all, so it was definitely the leg doors there shortened slightly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838488225-PCVVOD4LDOFE48QOFI83/IMG_9775.jpeg Emmett Build Pics Once it was loaded into my truck, I added more dropcoths around the base and tied it off to the shelves so it couldn’t tip over. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737845905329-YVSRYINTV7V17OW0ZRXP/IMG_9822.jpeg Emmett Build Pics On display at the school awaiting the raffle. My wife had the idea to include a picture of Emmett opened up because she realized people wouldn’t understand it was also a cabinet, which turned out to be a great idea because a lot of people were shocked when they saw the photo. http://www.greengatewoodworks.com/wayne-mudroom-desk daily 0.75 2025-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738786277385-RAZX9VGB1ATNNYJMTS30/IMG_9631+2.jpg Wayne Mudroom / Desk For this project the client contacted me looking to create a dual-function space in their front entry room. They needed storage for typically mudroom things (coats, etc) as well as a desk space for working from home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738786277385-RAZX9VGB1ATNNYJMTS30/IMG_9631+2.jpg Wayne Mudroom / Desk For this project the client contacted me looking to create a dual-function space in their front entry room. They needed storage for typically mudroom things (coats, etc) as well as a desk space for working from home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738786271105-GGYR9Y3CKLFEIQVB2D3E/IMG_9805a+2.JPG Wayne Mudroom / Desk The finished project has full length hanging storage in the tall wardrobe cabinet on the left side, and split storage on the right side with interior shelves inside the upper and lower cabinets. The desk features storage drawers below and open shelving above, with a desktop made from quarter sawn maple sealed with a marine-grade varnish. Custom straight-cut wainscoting on the back wall provides an extra level of detail. The paint color is “Terrain” from Sherwin Williams (SW 9613) http://www.greengatewoodworks.com/merion-station-closet-renovation daily 0.75 2025-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738787844741-XZH5EN94WT2I7MMZ7PU5/IMG_9436.jpg Merion Station Closet Renovation For this project the client wanted to increase the storage in their bedroom closet and make it more efficient. In order to create more space I removed the front wall of the closet and relocated the light switch to the adjacent wall. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738787844741-XZH5EN94WT2I7MMZ7PU5/IMG_9436.jpg Merion Station Closet Renovation For this project the client wanted to increase the storage in their bedroom closet and make it more efficient. In order to create more space I removed the front wall of the closet and relocated the light switch to the adjacent wall. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738787836376-IPTLUICF8BROACV3EAFZ/IMG_9515.JPG Merion Station Closet Renovation The finished project takes advantage of the entire width of the closet, and is about 10” wider on each side now than the original layout, and about 11” taller. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738787851337-DYC4M9LYC9RH8YDZHIFR/IMG_9521.jpg Merion Station Closet Renovation The left unit has dual hanger bars, while the right side features shelves for storing smaller items and dual hampers below. Under-shelf lighting illuminates every section of the new closet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738787860629-3PH7FMLPLZ6IPT43UEDD/IMG_9522.jpg Merion Station Closet Renovation The hampers pull out for easy access and are housed in solid maple drawer boxes. http://www.greengatewoodworks.com/welcome-marquee daily 1.0 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1500686085048-ZLX8OWVJ69CAOT9NUGYX/Mark+framing+2nd+floor+1217.jpeg Welcome https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552630923-TTLZBPXET5CPSRTHHBN7/IMG_1133.jpg Welcome https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477597496979-FEHXF71SLM27USFHKR62/Handmade+Furniture Welcome HANDMADE FURNITURE https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477933554847-H1IU8XNRMJ8UTTASDWI8/Zug+mantle+%281%29.jpg Welcome https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477623082192-R70KBQ4ZOGBS81EQ59UM/IMG_6954.jpg Welcome https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477933279533-0VUJM3KAIZV0RNOJOIO0/DEFINING+BUILT-INS Welcome https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477597915089-54X58K4117126CYHBP0X/image-asset.jpeg Welcome https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560421011264-5HV1CAYVARH8VJ8L661Z/image-asset.jpeg Welcome https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/8fe2ef0f-b835-420d-a498-413a8a982598/1F669C34-6A5D-4034-B76A-4768F7039326.JPG Welcome - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477600998842-KR3590HZQ9TAPAIML6R9/IMG_5969.jpeg Welcome https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477601057050-9D5UQYSO79V1R6W9QFNI/image-asset.jpeg Welcome http://www.greengatewoodworks.com/new-gallery-26 daily 0.75 2025-08-12 http://www.greengatewoodworks.com/my-mudroom daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844393484-AJAYRB3GWV0P2I3M6O2P/IMG_1419+2.jpeg My Mudroom A few years back I had installed brick floors in our mudroom along with lockers, cubbies, and a small bench, but the room remained unfinished for a while. In 2025 I was finally able to finish it up. The first step was to waterproof the dog shower prior to installing the brick floor and wall treatment. Thanks to Jeff Coppolino of Coppolino Construction for handling the installation of the dog shower pan, brick base, and the waterproofing membrane. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844393484-AJAYRB3GWV0P2I3M6O2P/IMG_1419+2.jpeg My Mudroom A few years back I had installed brick floors in our mudroom along with lockers, cubbies, and a small bench, but the room remained unfinished for a while. In 2025 I was finally able to finish it up. The first step was to waterproof the dog shower prior to installing the brick floor and wall treatment. Thanks to Jeff Coppolino of Coppolino Construction for handling the installation of the dog shower pan, brick base, and the waterproofing membrane. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844399520-OHKQSY3H1LSU6YVL1QPY/IMG_1724.jpeg My Mudroom For the walls we wanted to do a tall wainscoting. Since the dog shower would obviously have to deal with moisture, I made the wainscoting in that area out of Azek (PVC boards), so that it would be completely rot proof. All joints in that area were sealed using a PVC adhesive that bonds the boards fully, making it entirely waterproof. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844392655-PB6I6W2POSCDCO8AM7V6/IMG_1418.jpeg My Mudroom https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844398657-K6ZQ6PKCUH6V49T2IXY5/IMG_1723.jpeg My Mudroom Wainscoting was extended around the entirety of the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844462692-LLL0M1V6YG8X4TQ4MVYT/IMG_2008.jpeg My Mudroom After I had completed all the trim work and we finished painting the walls, my wife got to work stenciling. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844376389-6MNR7NVXSKK5LTD094AD/IMG_0665+2.jpeg My Mudroom The finished room turned out great, the stenciling added a really nice touch. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844382510-8E0K47Z5URN5ZXHHJWER/IMG_0695+2.jpeg My Mudroom Hooks around the room allow for plenty of hanging space, and the hooks inside the dog shower come in handy for towels or even hanging up raincoats to drip dry. Flagstone for the wall cap and shower threshold, provided by LS Stone Masonry Solutions, created a nice contrast to the surrounding bricks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844386950-J7DS6GZCSYPMGJ6AT84M/IMG_0701+2.jpeg My Mudroom A new mirror was added along with some smaller hooks below for keys, leashes, etc. The new black entry door offsets the light colors of the trimwork and walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844375585-AYSKXAA4DVS5A6FVB2EU/IMG_0633.jpeg My Mudroom My daughter was a big fan of the dog shower. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844380879-FFI907SQZPHCEVXOHZ11/IMG_0672+2.jpeg My Mudroom Sydney the dog was not as enthusiastic. http://www.greengatewoodworks.com/green-gate-woodworks-new-shop daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859338972-WWTCYFBQBTR8X9033JII/B85B93CF-65CF-45F7-BB51-3EDCEF946258+2+copy.JPG Green Gate Woodworks New Shop After many years working in a small two-car garage, I decided to build myself a new shop so I’d have more room and could make my work flow more efficient. I ordered a timber frame barn kit from Brooks Post & Beam and worked with them to customize the design to my requirements. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859338972-WWTCYFBQBTR8X9033JII/B85B93CF-65CF-45F7-BB51-3EDCEF946258+2+copy.JPG Green Gate Woodworks New Shop After many years working in a small two-car garage, I decided to build myself a new shop so I’d have more room and could make my work flow more efficient. I ordered a timber frame barn kit from Brooks Post & Beam and worked with them to customize the design to my requirements. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859486064-QAB3AFW6XQRXU4GE7924/IMG_7517+2.jpeg Green Gate Woodworks New Shop This was my original shop. Because I needed to still have access to my machinery and equipment while the new shop was being built, I came up with a plan to build around the existing shop and enclose it within the new one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859507434-TUGLJM9UBGQXURQY5HVC/IMG_7662+2.jpeg Green Gate Woodworks New Shop First step was to remove the front overhang of the roof so I could begin excavating. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859484259-R6FVZH932N2OJTTP5HM7/IMG_7510+2+copy.JPG Green Gate Woodworks New Shop I did the bulk of the excavation with my little tractor and backhoe attachment. Most of the new shop would extend behind and to the left of the original building, here I am excavating for the new floor area. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859549543-C55822GZ9SA69EIK0K5I/IMG_8076+2+copy.JPG Green Gate Woodworks New Shop For the footers I had to rent a mini excavator that allowed me to dig deeper and closer to the original building than my tractor could. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859565452-PNEKRJLNBQ6OYKKQGBMF/IMG_8091+2+copy.JPG Green Gate Woodworks New Shop After excavation was complete and rebar was installed, it was time to pour the concrete footers. The skid steer makes short work of pouring the concrete and is far easier than pushing wheelbarrows around. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859570145-RGAU2EONMOBE2YMGU7U8/IMG_8103+2.jpeg Green Gate Woodworks New Shop Once the footers were dry, I was able to start laying the first course of cinder blocks for the new foundation walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859606541-K28F29A3BBOLOJWN0RLT/IMG_8193+2.jpeg Green Gate Woodworks New Shop After many hours of masonry that made me appreciate my woodworking job more than ever, the new foundation walls were up and surrounding the old shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859495615-5UWAR1JHHPPDN0RIC4PO/IMG_7644+2.jpeg Green Gate Woodworks New Shop The timber frame kit arrived shortly thereafter from New Hampshire. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859337395-88Y2CNCKNEHL3SXJTZUA/580C4D08-21CB-4C2D-A8A5-61A9D552A13B+2+copy.JPG Green Gate Woodworks New Shop For unloading the truck, I got to learn how to drive a new toy, the Telehandler, also sometimes called a Lull. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859606888-XE1MBFOJPSGPL8J23LTD/IMG_8257+4.jpeg Green Gate Woodworks New Shop The timber frame kit was designed to go just above the walls of the original shop, so we removed the shop roof framing and tarped everything to keep everything dry inside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859619149-Z7WK3XJ445821MOPWQAN/IMG_8299+2+copy.JPG Green Gate Woodworks New Shop First post going up. Because the new framing had to pass over the shop while still landing at the correct height so the interior stairs would lay out correctly, it was important to get this first post set to the exact height required. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859619206-9KC5RN66IZ5OE9JADE8X/IMG_8303+2.jpeg Green Gate Woodworks New Shop Once we had our heights established, it was quick work framing the front wall. The timber frame kit is cut to exacting standards and went together perfectly. Since it was just myself and my helper Tom on this project, I set up my Genie, or material lift, on a pallet that was then strapped to the tractor. This material lift has an electric winch on it which made raising and setting the large framing members much easier than doing it by hand. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859394916-ZEAZO12LS5TI5VHP41TA/IMG_3448+2.jpeg Green Gate Woodworks New Shop However, since the tractor was tied up with the material lift, we had to muscle the framing pieces to wherever the tractor was. Not fun on a cold somewhat muddy job site, but there was no room in the budget for a second tractor. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859394068-OI39UNVRNOW9EZDX43M3/IMG_3450+2.jpeg Green Gate Woodworks New Shop Setting the rear walls. I installed a remote control on the winch on the material lift so I could operate it from up on the ladder while we shimmied the beams into place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859404868-YV0RWGY1T8BA8HGT076Z/IMG_3454+2.jpeg Green Gate Woodworks New Shop The entire timber frame kit goes together with minimal hardware, mostly its old school draw bore joints where a peg is hammered through slightly offset holes in the framing pieces to draw everything together tightly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859638064-KR95XX49XXMIT97ZDV7R/IMG_8333+3.jpeg Green Gate Woodworks New Shop First floor timber framing complete. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859651998-16FA78GEGJ727HUQNK0Z/IMG_8404+3.jpeg Green Gate Woodworks New Shop Next up we installed the second floor deck and began to frame the knee walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859662753-6EKRXLTW5CIQBNGW0HMS/IMG_8459+2.jpeg Green Gate Woodworks New Shop Here you can see the main posts for the roof going in. We used the material lift to load all our necessary materials up to the second floor before dismantling the lift and moving it up there as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859665139-IQL4RH8PBSG0NSNNN99C/IMG_8472+2.jpeg Green Gate Woodworks New Shop With the material lift on the second floor, we began setting the ridge beam sections. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859675385-K71K9Z26RS4R1WVB6VWY/IMG_8479+2.jpeg Green Gate Woodworks New Shop Once the ridge beam was set, we used the material lift to help drag the rafters up into position before securing them in place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859686867-YRLN7VCNB4R8Z1YOL3YV/IMG_8496+2.jpeg Green Gate Woodworks New Shop With the rafters in place we installed the in-fill framing on the first floor for windows, sheathing, etc. We also put some tarps up on the roof to help keep the rain and snow out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859424885-OI6IVPVM559XJ69XSILL/IMG_3521+2.jpeg Green Gate Woodworks New Shop Here you can see the original shop inside the new one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859700563-0K9ITM71AZGQPXNM0L1U/IMG_8560+2.jpeg Green Gate Woodworks New Shop Next up we installed the second floor in-fill framing and then started on the sheathing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859336374-8FX232UMMFY43VMPXHXR/22A56B07-6FAE-4251-AE48-F11FB2553080+2+copy.JPG Green Gate Woodworks New Shop The roof consists of a layer of 2×6 framing covered in Zip Wall sheathing. In this picture I’m racing to get everything closed in before a snow storm was supposed to hit, and to keep myself secure I broke out my old tree climbing gear and tied myself off to the nearby maple tree so I could move around safely without risk of falling. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859464035-S97KJ6MAZL1LPOGMYCLP/IMG_6986+2.jpeg Green Gate Woodworks New Shop Once the sheathing was installed and taped, everything inside was pretty well protected from the elements and I was able to start installing windows and a pair of temporary doors. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859465342-9PKBIK1RPJWK8GCR21OE/IMG_7106.jpeg Green Gate Woodworks New Shop While it wasn’t in the original design, my wife and I decided a pent roof across the front of the barn would look nice and would provide some protection for the new front doors I had in mind. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859375406-CTQI44A2XGCIF9GJVLYT/IMG_2546.jpeg Green Gate Woodworks New Shop Meanwhile, inside the shop I had removed the original shop walls, poured concrete for the new floors, and framed the staircase. The area under the stairs provided an opportunity to create a little space for Sydney the dog. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859375311-XT3ONH4CE50NX1RD9WKZ/IMG_2612.jpeg Green Gate Woodworks New Shop Sydney in her dog house https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859528650-XSVWYKX8E5D85VH9CFPD/IMG_8024+3.jpeg Green Gate Woodworks New Shop To replace the temporary set of front doors I had made, I found these reclaimed doors that were the perfect width for what I needed but were around a foot too tall. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859575336-MFYYKVOVUBMTPNVPEMXW/IMG_8117+2.jpeg Green Gate Woodworks New Shop So I rebuilt the doors to the new height I needed. It’s a little more complicated than just sawing off the bottom of the doors if you want to maintain the structural integrity of the doors, to see this project more in depth click here. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859724851-CD6OL7CZC0HOCMDP8KWT/IMG_8896+2.jpeg Green Gate Woodworks New Shop With both doors rebuilt to the correct height, I gave them a fresh coat of paint and installed them. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859739856-M138WMX1HF52EPKJGQLC/IMG_9155+3.jpeg Green Gate Woodworks New Shop New doors installed, plus capping on the barn is complete and I installed standing seam metal on the pent roof to match the metal roof on our house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859356668-VLBOCQWPZ7QX9G1BBSBG/IMG_1230.jpeg Green Gate Woodworks New Shop For siding I installed ABM panel metal siding from AB Martin in textured evergreen color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859358851-DYNPPOV7NR8482GH4PGH/IMG_1263.jpeg Green Gate Woodworks New Shop Completed siding on the side and back walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770902438933-FWTE4W385E3H1GVLYPUG/IMG_1267.jpeg Green Gate Woodworks New Shop The “finished” shop as of the summer of 2025, next up will be installing gutters and then stone around the bottom of the walls to match our house. http://www.greengatewoodworks.com/my-kitchen daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906693483-LWWKCVEDI7XU64OT0VBV/Screen%2BShot%2B2020-06-06%2Bat%2B10.24.11%2BAM.png.webp My Kitchen This is an elevation I drew prior to our kitchen renovation so I could show my wife what it would look like when it was finished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906693483-LWWKCVEDI7XU64OT0VBV/Screen%2BShot%2B2020-06-06%2Bat%2B10.24.11%2BAM.png.webp My Kitchen This is an elevation I drew prior to our kitchen renovation so I could show my wife what it would look like when it was finished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906677980-PTZJ84LP2TL8FES617JY/1217%2Bkitchen.jpg.webp My Kitchen The installed kitchen. I made all the cabinets, doors, and drawers in my shop. Eventually there will be a peninsula along side the last cabinet on the right which will have a butcher block top and will serve as a prep area for when I cook. The countertops in the picture are temporary plywood ones. I milled rough lumber from a maple tree on our property and will turn that into wood countertops once it is dry, which should be sometime in mid-2018. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906678044-BVCWIF5TXNDWGN73QYV4/1217%2Bkitchen%2B2.jpg.webp My Kitchen My younger daughter supervising me while I work on the kitchen installation https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906679567-N42ZIINYEYBPGDCGUJHQ/1217%2Bkitchen%2B4.jpg.webp My Kitchen These are the pull-out shelves my daughter was sitting on in the last picture. Typically I make my drawers with dovetail joinery, but in this case I wanted to do something different, so I made them from solid maple with a housed rabbet joint in each corner, and then pinned that joint with walnut dowels. These pull-out shelves hold all my cast iron pots and pans and function perfectly under that heavy load. This design worked so well I started to include it in all my built-in projects for clients who wanted drawers or pull-out shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906680659-1HEGM04C1HD5BNDA0SDM/1217%2Bkitchen%2B5.jpg.webp My Kitchen Part of the kitchen renovation included finding a place to keep our trash cans. I decided to utilize some dead space over the basement stairwell and made this recessed cabinet. With trash can on the bottom, paper recycling in the middle, and a container for bottles and cans up top, each container pulls out on drawer slides for easy access and emptying. The doors open either with traditional pulls (which were on backorder at the time of this picture), or you can push the doors in slightly which triggers a magnetic catch to push the door open if your hands are messy. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906679490-FZFOZO8V9AH6T476BI3P/1217%2Bkitchen%2B3.jpg.webp My Kitchen When I installed handles on the trash cabinet doors, I also installed a smaller pair down low for my kids to use. Here my younger daughter tests them out. http://www.greengatewoodworks.com/newtown-square-dining-room-builtins daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770909743071-SR70SSIN5GGPTNFUY6NB/IMG_0031.jpeg Newtown Square Dining Room Built-ins https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770909743071-SR70SSIN5GGPTNFUY6NB/IMG_0031.jpeg Newtown Square Dining Room Built-ins https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770909755945-GOO8Y0X4WB52F2392I3C/IMG_0072.jpeg Newtown Square Dining Room Built-ins This dining room built-in dry bar with wine fridge and fridge/freezer drawers serves as an extension of the adjacent kitchen for entertaining. The overlay, double-stepped, shaker doors and simulated, divide-lite, glass doors with custom, stepped grids were made to match existing kitchen cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770909760301-V0V0PP8QWL3KH0BDF1WJ/IMG_0073.jpeg Newtown Square Dining Room Built-ins Under-cabinet lighting illuminates the black walnut countertop, and the LED lights on top create a nice ambient glow. I also replaced the existing kitchen cabinet lights with new LEDs, so all lighting is uniform in color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770909766322-PKQP36KSTXBLH9NMGT3J/IMG_9951.jpeg Newtown Square Dining Room Built-ins “Before” pic http://www.greengatewoodworks.com/glen-mills-mudroom daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770911204540-400H666YAQJ9L05G492Q/IMG_0511.jpeg Glen Mills Mudroom I enjoyed working in this 1700s home to create an equestrian-inspired mudroom. Larger than my typical mudroom projects, this one wraps around the entire room and provides lots of space for large storage cabinets and plenty of hanging area. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770911204540-400H666YAQJ9L05G492Q/IMG_0511.jpeg Glen Mills Mudroom I enjoyed working in this 1700s home to create an equestrian-inspired mudroom. Larger than my typical mudroom projects, this one wraps around the entire room and provides lots of space for large storage cabinets and plenty of hanging area. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910925529-MKU6MD5YW3TOGVEGGXCN/IMG_0510.jpeg Glen Mills Mudroom I spent a good bit of time during the design phase making sure the various sections of the cabinet face frames and doors would align and flow together visually. It’s a subtle detail that will mostly go unnoticed; however, it was worth the effort because without it, the cabinetry would feel discordant. The main wall of cabinetry shown here has open storage below for baskets, and the cabinet on the far right extends behind the adjacent wardrobe, providing an additional 24” of storage, utilizing what would otherwise be dead space in the corner. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910893594-39H5LXYNORMGLXQDQC99/IMG_0498.jpeg Glen Mills Mudroom Black walnut - featured on the bench top, countertop, and backer boards for the hooks - was chosen to complement the floors and paint color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910902739-8Y8U88C48F3Q1D9MUL7I/IMG_0502.jpeg Glen Mills Mudroom Custom wainscoting ties the various sections of the room together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910930995-2ZB7U4DIIHZ9O42CIY3B/IMG_0512.jpeg Glen Mills Mudroom The rustic bridle hooks the client provided are a fantastic detail. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910914298-B01F50HRM17Z33MZ92KL/IMG_0506.jpeg Glen Mills Mudroom This wardrobe cabinet features hanging storage up top and two pull-out shelves for shoes in the lower portion. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910785366-2UX4M0ISK7OD19TWK0NP/IMG_0400.jpeg Glen Mills Mudroom “Before” pic http://www.greengatewoodworks.com/phoenixville-entertainment-center daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770913133914-G6JIVBFPQFQVSG4X1KXN/IMG_2576.jpeg Phoenixville Entertainment Center This living entertainment center features inset doors, a black walnut countertop, and upper shelving surrounding a central frame TV. Below the TV is an open area which houses the audio equipment and speakers, which are hidden behind a fabric covered front. That front is mounted on magnetic push latches, and will come forward for removal after being pressed inward. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770913133914-G6JIVBFPQFQVSG4X1KXN/IMG_2576.jpeg Phoenixville Entertainment Center This living entertainment center features inset doors, a black walnut countertop, and upper shelving surrounding a central frame TV. Below the TV is an open area which houses the audio equipment and speakers, which are hidden behind a fabric covered front. That front is mounted on magnetic push latches, and will come forward for removal after being pressed inward. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770913127366-YS9HPAQ9HFZEQYBB4MQO/IMG_2574.jpeg Phoenixville Entertainment Center https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770913418865-GOSQ0T7NOF9XLJ4QPBY2/IMG_2571.jpeg Phoenixville Entertainment Center Under-shelf LED lighting provides a warm glow to the room without creating glare on the television. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770914559285-D2W21G0RBNI7XE1S12YH/IMG_5305+2.jpeg Phoenixville Entertainment Center After I was finished the client was kind enough to send me this finish picture of it fully decorated. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770913115739-SOSWY3SCD6CD44WN2VEM/IMG_2439.jpeg Phoenixville Entertainment Center “Before” pic http://www.greengatewoodworks.com/merion-station-bedroom-builtins daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916042941-RRUKF7KPLCHJOFNOTOL3/IMG_1194.jpeg Merion Station Bedroom Built-ins This project for a repeat customer consisted of three distinct pieces spread out across a third-floor bedroom with very tight access up the stairs. All of these cabinets had to be brought in disassembled, then rebuilt onsite. This first unit is a built-in dresser with loads of drawers for storage and open upper cubbies. All carpeting in this area was to be replaced which is why I gave myself a little extra room when removing it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916042941-RRUKF7KPLCHJOFNOTOL3/IMG_1194.jpeg Merion Station Bedroom Built-ins This project for a repeat customer consisted of three distinct pieces spread out across a third-floor bedroom with very tight access up the stairs. All of these cabinets had to be brought in disassembled, then rebuilt onsite. This first unit is a built-in dresser with loads of drawers for storage and open upper cubbies. All carpeting in this area was to be replaced which is why I gave myself a little extra room when removing it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916034045-LE3SK4IF5P0N50X4O7C8/IMG_1075.jpeg Merion Station Bedroom Built-ins “Before” pic https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916047155-U5SRWU4GPJJIB2PR1N3B/IMG_1195.jpeg Merion Station Bedroom Built-ins This recessed bookshelf was added along side an existing closet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916032564-200HFGO6UAUSKW8J2MEB/IMG_1074.jpeg Merion Station Bedroom Built-ins “Before” pic https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770917062172-Q0NI56RSU0FRV8MQQ7CC/IMG_1199+crop.jpg Merion Station Bedroom Built-ins This angled bookshelf unit sits on top of an existing HVAC soffit that was in the room. Instead of trying to reroute all the ducts inside, I turned it into a window seat with a beautiful black walnut top, saving both time and money. Access was so tight coming up the stairs that the black walnut top had to be loaded in through the window. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916036857-WPO0EXDMTET1CW3DZTM5/IMG_1097+2.jpeg Merion Station Bedroom Built-ins “Before” pic http://www.greengatewoodworks.com/new-gallery-80 daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919071215-9H9S77MS632D9GQHCGQX/IMG_1833.jpeg Merion Station Built-in Bed, Closet, and Dresser This project consisted of a built-in bed with bookshelves at the foot- and headboards, plus a closet unit, and a built-in dresser. Drawers under the bed and below the footboard provide additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919071215-9H9S77MS632D9GQHCGQX/IMG_1833.jpeg Merion Station Built-in Bed, Closet, and Dresser This project consisted of a built-in bed with bookshelves at the foot- and headboards, plus a closet unit, and a built-in dresser. Drawers under the bed and below the footboard provide additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919060721-ZLO1B4LJL28B6IO6AVLC/IMG_1824.jpeg Merion Station Built-in Bed, Closet, and Dresser Undershelf LED lights in both sets of bookshelves create a soft light for reading. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919059828-NA9IKLYBY1ANKCXSPM6Y/IMG_1823.jpeg Merion Station Built-in Bed, Closet, and Dresser The closet unit consists of an upper hanging area with open storage below. The client was handling painting the walls and ceiling themselves, which is why it’s cut in along the walls but not finished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919036281-GFQ7RWI07V21NOZXN0O5/IMG_1421.jpeg Merion Station Built-in Bed, Closet, and Dresser https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919354576-HRHARFS8DPSK310JUNVJ/IMG_1836.jpeg Merion Station Built-in Bed, Closet, and Dresser The shorter footboard allows for an extra shelf compared to the headboard shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919053064-BMYUIDRRBEC78QO0OKQR/IMG_1424.jpeg Merion Station Built-in Bed, Closet, and Dresser “Before” pic https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919053070-2XGX4A1KXIZZKZJNFP82/IMG_1422.jpeg Merion Station Built-in Bed, Closet, and Dresser Another “before” pic http://www.greengatewoodworks.com/new-gallery-88 daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770921830665-U89DY9I5XWA4O40JOJ2X/IMG_3059.jpeg Merion Station Bedroom Closets and Window Seats A repeat client came to me with this project for their master bedroom. They wanted to replace their original Ikea wardrobes with something more permanent that would give them additional storage. The door knobs and drawer pulls were on backorder when I completed this project which is why they are not shown. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770921830665-U89DY9I5XWA4O40JOJ2X/IMG_3059.jpeg Merion Station Bedroom Closets and Window Seats A repeat client came to me with this project for their master bedroom. They wanted to replace their original Ikea wardrobes with something more permanent that would give them additional storage. The door knobs and drawer pulls were on backorder when I completed this project which is why they are not shown. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770921849275-VGF049WG405KGPV9PR96/IMG_3061.jpeg Merion Station Bedroom Closets and Window Seats All three closet units have hanging storage of varying lengths. The center unit has mid-length hanging storage, the right side has slightly shorter hanging space with an extra pull-out shelf behind the doors. The left side closet’s two upper drawer fronts are false, concealing a full length hanging area behind them. The false drawer fronts create a standard appearance across the entire project despite the varying hanging storage areas. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770921847501-4QKXSA8763JN266NDODY/IMG_3048.jpg Merion Station Bedroom Closets and Window Seats All three closets have LED lights inside controlled by a motion sensing dimmer in the ceiling, which illuminates the hanging areas when the doors are opened. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770921818638-R2RD9QLSLHBSVYTCF2TB/IMG_2795.jpeg Merion Station Bedroom Closets and Window Seats “Before” pic http://www.greengatewoodworks.com/contact daily 0.75 2022-10-10 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479809194570-VD6WJATCN06K7GB75NVM/IMG_1231.jpg Contact http://www.greengatewoodworks.com/custom-woodworking daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477660673787-63GE9J8ZUU3OMMX7XC5A/Zug+mantle+%281%29.jpg Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501520380345-PBKU8HAMZHY4GXICIGTQ/stephanie+ipe+deck+1.jpg Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501521486192-DX0HIXWG2KDNX3FOU8BB/wine+holder.jpg Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477660012214-W2IZYFDZRYU1LDFE61FW/IMG_3881.JPG Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/7d37a795-546e-426d-b1d4-7a4f37ea5c7e/666E5E9D-23C3-466D-A124-FA7E2F61208E.JPG Custom Woodworking - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537318864479-IB1SKQ5T3ZB3HYQX28SO/IMG_9106.JPG Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477937607031-WKQHIYYUV1I97D3TC9EW/image-asset.jpeg Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606150889404-H8KNCEQS5QF9BBGMVC7F/A673019F-D737-4D2C-96D0-BC32E7CD9EBE.JPG Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510624253524-LUHLN10902OKKHBN7NYR/IMG_5199.jpg Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544044703625-TKIBEEY42EYFII0F0KO6/IMG_0177.jpg Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544309676813-DR1KHIYQHC154QOGIMWX/IMG_9533.jpg Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574447516224-LEI7VNJUAUB06TB97S36/image-asset.jpeg Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554144767202-AW2S2JLOMQLNRW6SPRO2/IMG_1564.JPG Custom Woodworking https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/ac5f7d23-5d83-4de3-ac0f-3cded90273e8/IMG_9155.jpg Custom Woodworking - 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Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/2d5344a3-1870-4849-a7c2-0336e2eac1d9/B2B0CDB6-1498-4BEC-A3A3-C15FC34DB02A.JPG Defining Built-Ins - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/34c8f44e-ea54-405f-9ea6-8b48d3ca8614/IMG_9515.JPG Defining Built-Ins - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/87dafcbf-a500-49b1-994a-cbf26601508e/Kaplan1+crop.jpg Defining Built-Ins - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491614220328-RYPFUWNR0S3IIN1WJ5CU/IMG_9970.jpg Defining Built-Ins https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083644387-XS848J4BH7ZCFV8TF4FD/IMG_9228.jpg Defining Built-Ins http://www.greengatewoodworks.com/green-gate-woodworks-2 daily 0.75 2017-08-27 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479809054675-MHUYD36664E8M2U4SP05/Buffet-Barnwood+5-13-16+IMG_1646.jpg Our Work https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477597496979-FEHXF71SLM27USFHKR62/Handmade+Furniture Our Work HANDMADE FURNITURE https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477933554847-H1IU8XNRMJ8UTTASDWI8/Zug+mantle+%281%29.jpg Our Work https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477623082192-R70KBQ4ZOGBS81EQ59UM/IMG_6954.jpg Our Work https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477933279533-0VUJM3KAIZV0RNOJOIO0/DEFINING+BUILT-INS Our Work https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477597915089-54X58K4117126CYHBP0X/image-asset.jpeg Our Work http://www.greengatewoodworks.com/project-gallery-page daily 0.75 2016-03-21 http://www.greengatewoodworks.com/story daily 0.75 2017-11-20 https://images.squarespace-cdn.com/content/v1/5755bccb8259b515333df0e1/1466115070758-QDGTM4SMWWF57NK026OU/Stocksy_comp_543118.jpg — Story — https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1511144332974-0DFPZG0J4UW355OI3AZC/IMG_4185.JPG — Story — - test test asdfa asdfasdfa s http://www.greengatewoodworks.com/test-page daily 0.75 2018-01-30 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087714999-UMIHKK1TCQ98Z0Q57YE6/317+oakwood+-+wide+exterior+front+shot3+with+columns.jpg Devon House This is a custom house we built in 2007. While the photogragh is a little drab because it was winter, it's the only time of year to see the whole house because the leaves are off the trees. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087731077-NE135RVMTHVS4SQBFCM0/IMG_5101.jpg Devon House Wide shot of the kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087732117-CNVVLWSYKU014RFHL8PU/IMG_5102.jpg Devon House Brazilian granite countertops https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087736133-9GKQK55W3CID5OTEV8OV/IMG_5107.jpg Devon House Another shot of the kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087716501-LH0M6QCE27V441HS0F7F/IMG_5059.jpg Devon House Me, in the family room, during our open house. I think I was giving directions to somebody. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087718244-H5Y3D8REFHI2XPCNJMLP/IMG_5064a.jpg Devon House French pocket doors between the formal living room and the dining room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087720866-FFYG0UJKKZ7YR340WL8B/IMG_5074.jpg Devon House Staircase to the second floor https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087719895-4TJPK3M04HT7D024AKGE/IMG_5073.jpg Devon House Walnut inlay in the foyer floors https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087723808-GULWU89BRFSCUM0I1L9O/IMG_5083a.jpg Devon House Master bath shower https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087728112-I98H226JDO6OT25FY2JC/IMG_5100.jpg Devon House Front porch https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087714281-N7D944MEBJNRJH0HFJNW/317+Oakwood+-+exterior+shot+-+all+done.jpg Devon House This is probably my favorite picture of this project: the finished house and landscaping. http://www.greengatewoodworks.com/chester-springs-entertainment-center daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547898221-QGE559USYGKSBSSDMFTA/IMG_4134.JPG Chester Springs Entertainment Center I acquired a truckload of old house beams, ranging in age from 100 - 200 years old. I took a few of them to create shelving for an entertainment center project I was commissioned for. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547894236-G18LBS3ZLFXMIPUWM4IL/IMG_4189.JPG Chester Springs Entertainment Center I resawed the beams down to the size thickness I needed for the shelves, and then got to work gluing the up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547904188-IUG6TYAOTW3PQXSQC6AW/IMG_4331+2.JPG Chester Springs Entertainment Center This is a before and after of one of the panels glued and clamped, and then after it was sanded and finished with varnish. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547908909-MVZV5DMOIS3D1UJDOQU9/IMG_4282.JPG Chester Springs Entertainment Center Another of the finished larger shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508547912492-TB5V44X5KRAWKX3UF4VU/IMG_4444.JPG Chester Springs Entertainment Center The finished product in its new home. The metal framework was fabricated by JGM, Inc. http://www.greengatewoodworks.com/chester-springs-kitchen-nook daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496869977640-SOMHZ7J2W7O98BLMUUWD/IMG_5971.JPG Chester Springs Kitchen Nook I received a call from a client for several projects they had in mind. One of those was a new dining area in their kitchen. They commissioned me to create a built-in bench, a stone accent wall, and a custom live-edge table. This is the area prior to work beginning. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496869985546-CT2ZIVO0FJSELXTLIS7U/IMG_5986.JPG Chester Springs Kitchen Nook To begin the stonework, we removed the drywall and installed tar paper and wire mesh over a plywood backing. After that, a brown coat was installed which serves as a base layer for the stone. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496869995074-FL9I6VF30510RIWPFVRZ/IMG_5992.JPG Chester Springs Kitchen Nook We used a 2" veneer stone to match some existing stone accents in the home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496869999503-QAOO6YEP417EWMER6A9X/IMG_6808.JPG Chester Springs Kitchen Nook After the stonework was complete, I began work on a built-in bench seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870006002-4CAZMTULKXQE20ENH7AD/IMG_6857.JPG Chester Springs Kitchen Nook With the bench tops on and the back panels being framed up, it begins to take shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870015562-N2Z41TNH09Y3MPYW99PC/IMG_6871.JPG Chester Springs Kitchen Nook I trimmed the bench out to match the existing trim scheme of the home and used beadboard paneling to complete the back and lower face. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870016869-KE2VPOU5FTSGFE2QWTAQ/IMG_6889.JPG Chester Springs Kitchen Nook The bench was painted with a white chalk paint and antiqued using a mix of dark and clear waxes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870524499-LOBLFFUT08QVDXCD717C/IMG_5969.JPG Chester Springs Kitchen Nook The final part of this project was fabrication of a custom dining table. The client chose this white oak flitch, shown here with me and my shop assistant. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870523385-9RUFKHVT3NQDYJ6K4LU3/IMG_6127.JPG Chester Springs Kitchen Nook Trimming the slab to length. After this I flattened it using my router sled. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870550076-C694I91UQKDYWKQG6MBH/IMG_6479.JPG Chester Springs Kitchen Nook I inlaid a piece of plexiglass in the bottom of the slab under the central hole in order to fill it in. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870567804-EKX7T2NNP8DJJFONL0PT/IMG_6520.JPG Chester Springs Kitchen Nook The client had a tree of life emblem she wanted embedded in the hole, so after I closed the bottom off with plexiglass, I installed the emblem in the middle of multiple layer of crystal clear epoxy. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870568871-UOW8NIUH8Q7VUX9GTWCC/IMG_7289.JPG Chester Springs Kitchen Nook After staining and clear coating the table, I polished it to the desired sheen. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870328981-P52OL4XI9ZAJUJ6HID6H/IMG_1190.jpg Chester Springs Kitchen Nook Wide shot of the finished project https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870331884-3A88NC8ZRSD75K1Y9J47/IMG_1250.jpg Chester Springs Kitchen Nook The finished bench seating https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870332445-OBY9O4ZRVC0A1DW68BX1/IMG_1253.jpg Chester Springs Kitchen Nook The bench tops lift up to reveal storage space inside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870329854-ESLWZFNS99X8X5XP3BCX/IMG_1197.jpg Chester Springs Kitchen Nook The finished table in its spot along with the custom cushions the client had made for the bench seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870329901-WCX83G782QFCWKQ8GO5B/IMG_1214.jpg Chester Springs Kitchen Nook Looking down the live edge of the table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870330643-5NQR7VKPB12SHHLNLWUY/IMG_1221.jpg Chester Springs Kitchen Nook The table base was fabricated by John Parker of The Painted Garden, Inc based on my design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870331689-UCU3VIU6N4H6TYK71UJT/IMG_1247.jpg Chester Springs Kitchen Nook A view of the embedded emblem https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496870329035-T6T0QY7W9UAWIFKV4DV1/IMG_1188.jpg Chester Springs Kitchen Nook Another finished shot of the entire area. Through the arched window you can see the existing stone we matched for this project. http://www.greengatewoodworks.com/gladwyne-builtin-closets-window-seat daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552681665-6J7X9TJLA1FDQ87VGESD/IMG_0594.JPG Gladwyne Built-in Closets & Window Seat Before picture of the room. Due to a lack of storage in this 100+ year-old Gladwyne home, the client requested two large closet cabinets along with drawer bases and upper cabinets for additional storage, as well as a window seat for their daughter’s room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552681710-3DXIFLOI8UOMHB58URH9/IMG_0603.JPG Gladwyne Built-in Closets & Window Seat After narrowing down possibilities with the client, I came up with this design to best meet their needs. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552691817-MZSXEJA6DLKSPILZ02WN/IMG_0645.JPG Gladwyne Built-in Closets & Window Seat One of the assembled cases. After all the cases were finished, I began work on the drawer boxes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552706938-95Y8H8ER2W71F5DZX9A8/IMG_0749.JPG Gladwyne Built-in Closets & Window Seat Drawer sides dovetailed and grooved to hold the bottom pieces https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552697192-JHJRFOD59S9MVCGR0ISX/IMG_0725.JPG Gladwyne Built-in Closets & Window Seat Part of the project required me to build a plywood torsion box. Here it is without the lid. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552700526-GLHM4UAWQBONPA723YKI/IMG_0728.JPG Gladwyne Built-in Closets & Window Seat ...and here it is with the lid. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552712486-7IS2MYPIPU9142L69X6Y/IMG_0790.JPG Gladwyne Built-in Closets & Window Seat Lower units going in   https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552717525-2Y1CLFSIPGX6EOSMYJU8/IMG_0814.JPG Gladwyne Built-in Closets & Window Seat Middle units installed, along with the center drawer unit. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552716689-98IXWXY2R9D8JUKB8SCF/IMG_0873.JPG Gladwyne Built-in Closets & Window Seat Upper cabinets, baseboard, and drawers fit and installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552746558-AP6NREWMTVBPN7N6XR37/IMG_2265.JPG Gladwyne Built-in Closets & Window Seat Finished shot looking across the face of the window seat. This center unit extends 2” beyond the face of the side cabinets to give the finished piece a little more visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552794499-54WQRT0VW2W5IIO1L6MV/IMG_2271-72.jpg Gladwyne Built-in Closets & Window Seat The torsion box from earlier serves as a false drawer that provides a step up to the extra tall window seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552798131-811H43GRRKY0UX9EXB8U/IMG_2269.JPG Gladwyne Built-in Closets & Window Seat All of the drawers have soft close slides, while the hidden step has heavy duty slides rated to 500 lbs because I overbuild everything. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552813215-CBY6G12LTM2UPNUAO49I/IMG_2278.JPG Gladwyne Built-in Closets & Window Seat The client opted for these crystal knobs with a satin nickel base for their hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501552746693-6XL7QWAG6F068ZR93NBA/IMG_2261-62.jpg Gladwyne Built-in Closets & Window Seat Finished shot of the completed project http://www.greengatewoodworks.com/wine-totes-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501520907589-RGM9LH630TLF0OG0KIVC/wine.jpg Wine Totes Despite what it looks like, I'm actually working and not just drinking myself silly. My daughter's nursery school was having a fundraiser where each class put together a basket to be auctioned off. Our class's theme was "wine," and my wife asked if I could make something to hold the wine bottles, so I got to work designing a carrier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501520775181-7RX7UOZCKQRFDRVVA496/IMG_2179.JPG Wine Totes I based my design on vintage tool carriers and shaped the end panels to mimic the shape of a wine bottle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501520459888-A7COFOD7ILZ4OG1GCAAC/wine+holder.jpg Wine Totes The finished pair of wine carriers ready to be auctioned off. Each one is made of solid maple with through-tenon joinery, and the bottoms are also set into grooves along the lower rails for additional strength. http://www.greengatewoodworks.com/haverford-outdoor-beam-table daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543879552-41E16LZYMG69Y7HRNDTC/IMG_3940.JPG Outdoor Beam Table A client came to me with an old firewood holder they wanted to repurpose for an outdoor table. She chose some old barn beams I had in the shop to make up the table top and lower shelf. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543876442-JSQHL2155GXL4YEPK3LY/IMG_3942.JPG Outdoor Beam Table The beams weren't wide enough to span the table base, so i joined up two pieces for the top and two for the shelf, keeping the cut sides in the middle so that the existing patina was retained. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543902386-4YOZPGK3SKN2IA0U8V33/IMG_3983.JPG Outdoor Beam Table The cut ends of the top and shelf needed to be antiqued to match the other faces of the wood. I experimented staining it with some tea, but that didn't get the look I wanted. So I took another approach and burned them with a torch, as shown in the next video.   https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508543903577-SOXLQUG0OVYX0ITIJ1DB/IMG_4137.JPG Outdoor Beam Table With multiple coats of spar urethane, the table is ready to be used outside. http://www.greengatewoodworks.com/berwyn-cedar-grid-front-fence daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608742531-6LSTCWZSB7ZML3ON3SM3/IMG_4768.JPG Berwyn Cedar Grid Front Fence I had previously made a cedar grid fence for a client, and they asked me to create a smaller version for the front of their property. These bundles are the milled cedar ready to be shaped into the individual grid pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608750587-ZN48EMWIFD2YMRQQN1SY/IMG_4813.JPG Berwyn Cedar Grid Front Fence I assembled the grids taller than they needed to be and then trimmed the bottom off to match the grade of the property. We took elevations on the property at the locations for each panel and used this information to calculate the necessary angle for the bottom of the panels. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608749598-4M5M5YN6DYYBSPL233CN/IMG_4825.JPG Berwyn Cedar Grid Front Fence One of the assembled panels with the angled lower rail complete. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608762060-817PEBM57689D3ETT57B/IMG_4898.JPG Berwyn Cedar Grid Front Fence All the panels laid out end to end on my driveway to check their alignment. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608761017-RB6K8SND9OCDHHNUF938/IMG_4998.JPG Berwyn Cedar Grid Front Fence Installation day with a lot of help from the guys at Doyle McDonnell, Inc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608773845-7HKD7DMMBIPEZHTKDD7Q/IMG_5196.jpg Berwyn Cedar Grid Front Fence Completed fence on the left side of the driveway. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510608774501-4GVMBMMI6OUPZFX53O6M/IMG_5199.jpg Berwyn Cedar Grid Front Fence A single panel on the right side of the driveway ends into an existing garden bed. http://www.greengatewoodworks.com/chester-springs-mudroom-pantry daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250463839-98EE3Q1ZCZ7IQ39MATPI/IMG_6414.JPG Chester Springs Mudroom & Pantry I was commissioned by a client for several different projects, one of which was a set of mudroom lockers with a live edge walnut bench top. This is one of three slabs I worked with, shown here after I milled it down from rough lumber and was starting to layout my cuts. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085398969-3KXA7EGR4ZVZVN7M2CBW/IMG_1141-42-crop.jpg Chester Springs Mudroom & Pantry Looking down the finished lockers https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085399262-4TT2F6OG9ZVMHJ9BBK1F/IMG_1147.jpg Chester Springs Mudroom & Pantry A closer shot of the live edge of the walnut bench top https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250328597-OVBD99XAEYHZL1HBXQK9/IMG_1162.jpg Chester Springs Mudroom & Pantry The wall adjacent to the lockers received custom wainscoting I milled and fabricated in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250350623-PVG6D3VQ6HW22WG9DQSH/IMG_1169.jpg Chester Springs Mudroom & Pantry A closer shot of the cubbies and the locker hardware https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250306020-6FTE6YFVNLG2VKORCT19/IMG_1135R-37.jpg Chester Springs Mudroom & Pantry A wide shot of the finished lockers https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250379415-W9JGKLYC6PZ9OEMYQNSM/IMG_1185.jpg Chester Springs Mudroom & Pantry Just off the mudroom is a pantry that I fit out as the second half of this project. The pantry has a 10-lite french door and an occupancy sensor that turns on the overhead and under-cabinet lights automatically. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493250405687-GXTRL56EFW4D9F9QD29F/IMG_1174.jpg Chester Springs Mudroom & Pantry The pantry cabinets feature adjustable shelving, a maple countertop, and custom crown molding to match that of the lockers in the mudroom. No doors were added to the cabinets because they would take up too much room when opened in this small space. http://www.greengatewoodworks.com/haverford-banquette daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515726483-3RDDKDZTBYVSBM3ELF94/Sold+5.jpg Haverford Banquette This banquette is part of a larger project that included a kitchen table; pictures of the entire project can be seen here. The banquette has solid rock maple tops to match the table I made, and a simple flat panel design on the base and back to match existing paneling in the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515726477-OOOY83BV37DNJXYMQ29T/Sold+4.jpg Haverford Banquette The bench tops have concealed Soss hinges and open up for additional storage space inside. At the far right side there is a recessed shelf that houses two outlets and provides an area to hide away phone chargers, etc. http://www.greengatewoodworks.com/cedar-fence-hanging-planters daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837361213-Q948C6U4BV4EIY7P6RAQ/IMG_9713.JPG Cedar Fence & Hanging Planters I was contacted by a client looking for a custom fence with moveable planter boxes. This is the original fence that was removed to make way for the new one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837357308-XGMYWMX15ZUNMHHUEFU1/IMG_9703.JPG Cedar Fence & Hanging Planters I made up a couple two-sided cedar fence panels using horizontal slats secured to central stiles. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1480167586170-5N1TCONON2P09IYLDWMJ/IMG_9577.JPG Cedar Fence & Hanging Planters For the planter boxes I made up custom hanger hardware in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837364465-Y5KDRLV4GTY29KMGH5RR/IMG_9764.JPG Cedar Fence & Hanging Planters Planter boxes with hardware attached https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837367255-2OODHD3MPTINL711T2H1/IMG_9887.JPG Cedar Fence & Hanging Planters Picture of the finished project. The tall end post serves as an anchor point for a sun-sail that was on back order at the time of this picture. http://www.greengatewoodworks.com/mahogany-outdoor-table-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477780834843-KXPN5KWAZBZ1JF4QJLQ0/IMG_4710.JPG Mahogany Outdoor Table The client’s original table was falling apart due to rot. I suggested building a new top from Brazilian mahogany because of its ability to withstand the elements. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477780837166-0WGRU0PJBPYCQN65MK9A/IMG_4789.JPG Mahogany Outdoor Table The new top assembled and sanded down https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477780839122-9CA83D5BJ5VZJ0TJ5WSM/IMG_4821.JPG Mahogany Outdoor Table The finished table delivered. I reused the legs at the client's request and added a central hole for their umbrella. http://www.greengatewoodworks.com/inwall-built-in daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514683173-JLRL8XCMGLXP5AOXCV01/Opie+built+in1.jpg In-Wall Built In This project came to me from an old college friend who was looking for a built-in cabinet to provide more storage space in his early 1900's Folk Victorian home. We worked together on a design that would provide him with the storage space he required while blending into the existing trim scheme and decor of the home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514683070-VJXDER751QZUDANMYL9I/Opie+built+in+2.jpg In-Wall Built In The upper cabinet area provides an area for long term storage, while the drawers are for more day-to-day use. The open space at the bottom of the cabinet provides an area to store a cable box for the neighboring television. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514683076-JU43GIZ9W8ZIIK1UWSWC/Opie+built+in+3.jpg In-Wall Built In All the drawers are solid maple with hand-cut dovetail joinery to last a lifetime. http://www.greengatewoodworks.com/malvern-addition daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144713412-ZJH1OYSY2CIJBTLGFXAG/marino+before+panorama.jpg Malvern Addition This job was brought to us by a fellow contractor who wanted us to build the outer shell of this addition. Once it was up and weather-tight, he would complete the interior renovations. "Before" picture of original sunroom and deck during the initial stages of demolition. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144651945-EUP9PS3AHQU6QT4OQQEI/Marino+-+excavation2.JPG Malvern Addition The original house didn't have a full basement, but the new addition would. This required us to excavate below the foundation of the main house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144670530-W2F8JILFPC4CMOTKNNKC/Marino+-+foundation+form+install3.JPG Malvern Addition Set up of forms for poured basement walls https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144704712-UUHJNUL7L8RCWA9J4DPG/Marino+-+underpinning+forms6.JPG Malvern Addition Underpinning forms - since we excavated below the foundation of the existing house, we now needed to support it. This was done by pouring a concrete wall in small sections underneath the existing foundation; each section is tied together with rebar to make the finished wall a solid unit. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144666163-K6S3W485GT4W9TCOL3FR/Marino+-+floor+pour2.JPG Malvern Addition Basement floor going in; the finished underpinning wall is on the left. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144668725-QJBH52OFVL01I6CJUFQG/Marino+-+floor+joists2.JPG Malvern Addition Floor deck installed https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144659497-O2FMSZ2A8OO7N7Q0D8ZV/Marino+-+exterior+shot4.JPG Malvern Addition Walls going up and roof framing https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144704497-DC2A5F5QNZ4FUCMPL8CB/Marino+-+stucco+brown+coat2.JPG Malvern Addition Basecoat for stucco application https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144637017-KT4D7WECDS2PHF53540Q/IMG_5832.jpg Malvern Addition Shot of the finished exterior https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144638555-ZUKF4SXZMHH1FVVMB9GS/IMG_5884.jpg Malvern Addition Finished shot of the copper porch roof and cupola   https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144638439-TPSB7SXDXRKGUFEUZ12L/IMG_5885.jpg Malvern Addition Closer shot of the cupola https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144637384-KCS0IQT8OYZYOFXRRJWF/IMG_5836.jpg Malvern Addition Shot of the finished porch https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144637433-N2QFKBTA3E0A8ZACMVDK/IMG_5843.jpg Malvern Addition Looking across the finished porch https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479144637114-9IOJSRB50QFYSE4MPVSN/IMG_5834.jpg Malvern Addition Another shot of the finished porch http://www.greengatewoodworks.com/chester-springs-farmhouse-mbr-builtins daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626499586-W2YEW4MQEAW7YW9VNZ3O/IMG_5534.JPG Farmhouse Bedroom Built-Ins A client came to me with this design they had drawn for a set of built ins for their master bedroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626498600-9CQ4IW8M55LKU0Y11YT9/IMG_4099.JPG Farmhouse Bedroom Built-Ins Installation of the lower cases. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626498753-XF3MF7D4WXT6I9V1F8GL/IMG_4372.JPG Farmhouse Bedroom Built-Ins After the upper cases were set, doors were hung, and the end panels were installed my part of this job was complete. The clients would handle the installation of the crown molding and baseboards, as well as installing the pulls and painting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626501911-TZWZW24RG1JD0YLT98F8/IMG_5479.JPG Farmhouse Bedroom Built-Ins The finished product. The client did a beautiful job with the trim and finish work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510626499075-6ZJSM5P5B83GSRT4TQ77/IMG_5496.JPG Farmhouse Bedroom Built-Ins Close up of the beaded face frame detail that was included to match existing cabinetry elsewhere in the house. Little details like this make a big difference in the finished product. http://www.greengatewoodworks.com/sliding-lattice-panel daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491617492119-NDI97BN69XA4ZSZGUPHX/IMG_6968.jpg Sliding Lattice Panel As part of a larger deck renovation, I made this sliding lattice panel that provided access under the deck for hot tub maintenance. Space restrictions would not allow me to hinge the access door like I might normally, and I didn't want to do a traditional slider setup where the panels are offset because that would not match the rest of the panels around the deck. Instead, I designed a track system that I had John Parker from The Painted Garden, Inc fabricate for me that had the access panel pass behind the neighboring panel while in use, but still allowed it to sit flush when not in use. A video of it in action is at the end of this gallery. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491617484925-FYWQJ4PKPK4149JXEJZL/IMG_6967.jpg Sliding Lattice Panel Here you can see how the access panel passes behind the neighboring panel when in use. http://www.greengatewoodworks.com/berwyn-builtins daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083931035-BA1PQWXM6L7ZU2TM4R4P/IMG_9228.jpg Berwyn Built-ins For this set of cabinets, the client wanted plenty of storage along the bottom with a series of open shelves and cubbies on top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083928545-B3XAFUEM05A1GD20WMPJ/IMG_9232.jpg Berwyn Built-ins They also wanted an area to house their TV and other electronics. I designed that area to extend forward beyond the adjacent cabinets to provide visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083955217-ZGT6XYFPTNUHUX6C9L37/IMG_9251.jpg Berwyn Built-ins Closer shot showing some of the door and trim details https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083936183-8TIFO53ZW9D1571WH2IR/IMG_9237.jpg Berwyn Built-ins Bump out detail on the countertop https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083939699-B2GAUOJ6FFIW8DB59OZ2/IMG_9241.jpg Berwyn Built-ins In the first round of design this was intended to be a desk area, but it was later changed to cabinets. Now it seems to have become a bar, which is always a good move. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479083948282-CLS4JDCV78ZWEU63WJZM/IMG_9247-R.jpg Berwyn Built-ins The client wanted the built-ins to frame the doorway, which you can see with this view into their dining room. The whole piece was tied together with a small crown detail and baseboards to match their existing trim. http://www.greengatewoodworks.com/wayne-mbr-renovation daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524298880-3KCYD6DABZ4BJ4DUP3BR/IMG_1367.JPG Master Bedroom Renovation Ann Forster of Ann Decker Design brought this bedroom renovation job to me. Her clients wanted to update their master bedroom with an enlarged closet and some built-ins. These are the two original closets. A new, larger closet will go in place of the left-hand closet, and the right-hand closet will have the door swing reversed for easier access. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524301868-AMZB5LS3H6D8IWQYW768/IMG_1382.JPG Master Bedroom Renovation Old closet removed https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524302642-MEI7WOBGNU4L1I08IT27/IMG_1436.JPG Master Bedroom Renovation New closet framed in and drywalled https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524304287-13G3NH5F4CHX034WTHXF/IMG_2501R.jpg Master Bedroom Renovation Finished shot of the new closet, tall shoe cabinet, and radiator cover. The double doors on the closet were originally single doors in the home and were repurposed for this closet. I also made custom door casing and baseboards to match the existing trim scheme. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524304797-LH7DJYOF7I5G0RIOU6X4/IMG_2502R.jpg Master Bedroom Renovation Shoe cabinet opened up shows lots of adjustable shelving for ample storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524304234-HL1CI3RQEBQZ61GU95JX/IMG_2500R.jpg Master Bedroom Renovation The newly enlarged closet opens to reveal multiple hanger rods, a central built-in with inset drawers and adjustable shelving, and a custom shoe rack for additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524298480-NPZKX8E1CJ3AX5PL0H65/IMG_1371.JPG Master Bedroom Renovation Before shot of the other side of the room. The plan called for two built-in bookshelves to connect over top of the bed, additional overhead lighting and wall sconces, and a window seat to the right. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524303563-QTGEKT1UWEYZTR88KET7/IMG_2481.jpg Master Bedroom Renovation Finished shot of the right side of the bedroom. Each built-in features two inset drawers and a sawtooth adjustable shelf system. The radiator cover matches the other one on the far side of the room. The window seat opens for additional storage within. A cushion for the window seat was in the works at the time of this picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524303487-422IANA7DB5ENVU40CXL/IMG_2484.jpg Master Bedroom Renovation The left side of the bedroom has a matching built-in bookshelf. The closet shown here is the original closet from the first picture with the door swing reversed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501524302670-NTS8Z9VUC83Q85PSESGV/IMG_2478.jpg Master Bedroom Renovation In this wide shot from the doorway, the two bookshelves frame the bed nicely. As usual, all the drawers I made for this project are solid maple with hand-cut dovetail joinery. All design and decorating work by Ann Forster of Ann Decker Design. http://www.greengatewoodworks.com/philadelphia-bifold-doors daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615386632-3RWE4DXQMZRFR53C0EGA/IMG_99550+AllDoorsClosed.jpg Shop Bi-Fold Doors This is part of a larger shop renovation I did for a client; you can see the rest of the project here. The three doors to the left of the wide cabinet door are a raised panel bi-fold door system I designed and created specifically for this job. They provide access to a water shutoff and pressure relief system while not eating up unnecessary floor space. A video of them in operation can be seen at the end of this gallery. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615386954-ARMZMO2BM36W1LAJW69F/IMG_99550+FoldingDoorsTotalOpen.jpg Shop Bi-Fold Doors When fully opened the allow access to the main water shut off for the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615334349-KYNO2S8V34OMFDIH6UDG/Bifold_raised_panel_doors+copy.gif Shop Bi-Fold Doors A GIF video showing the operation of the bi-fold doors. http://www.greengatewoodworks.com/berwyn-cedar-grid-fence daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518069227-6EH9O76VOO7YVL0Q1CT6/stpehnaie+fence+7.jpg Berwyn Cedar Grid Fence I received an order for a large custom fence - about 300 lineal feet to be exact - with open-grid panels made of solid cedar. Here is some of the raw material after the initial stages of milling. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518069011-4Z2U41DVS7WIASS9OJ28/stephanie+fence+6.jpg Berwyn Cedar Grid Fence Every piece of the panels was dadoed for a half-lap joint for increased strength. My small shop started filling up with parts very quickly.   Next up is a short time-lapse video of a single panel being assembled. Showing about thirty minutes of work, it was one of 40 panels that had to be assembled, plus a few gates. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518068728-L170A8HUPJKTBM8SQER6/stephanice+fence+5.jpg Berwyn Cedar Grid Fence Loading the panels for delivery to the site https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518068970-A9UVWI1I0M70CYURCNXA/stephanie+fence+4.jpg Berwyn Cedar Grid Fence Fence panels during installation. In order to follow the grade, we stepped the panels up as necessary, always maintaining alignment of the grids. The posts will be finished off with cedar caps painted to match, and landscaping will be used to fill in any gaps along the bottom rail. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518068351-QPAXUVXR4G6F5BT7VXAL/stehpanie+fence.jpg Berwyn Cedar Grid Fence After the masons were finished with their work, I was able to come back and install the final sections of fence that sat atop the walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501518068386-RM197QLZ9CJVWJZKQQHC/stepanie+fence+gates.jpg Berwyn Cedar Grid Fence An arched gate provides the main entry area to the back yard. There is another single gate on the far side of the property, along with two sets of double gates to allow mowers and other equipment into the property. All the latches and hardware were custom made by Rocky Mountain Hardware. http://www.greengatewoodworks.com/chester-springs-flitch-table daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782189286-D3XO1DT22AJQTPEM9OWG/IMG_1197.jpg Chester Springs Flitch Table As part of a larger kitchen nook renovation, I made this custom dining table from a white oak flitch. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782189379-LLOEEFJ39O2G6D7LQAZT/IMG_1214.jpg Chester Springs Flitch Table Looking down the live edge of the table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782189733-ZH0WRL4JN87TGWOCO6ZP/IMG_1221.jpg Chester Springs Flitch Table The custom base was fabricated by John Parker of The Painted Garden, Inc based on my design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782190151-765ALJ13BGOVVVEYTPHK/IMG_1247.jpg Chester Springs Flitch Table Embedded in the central hole of the table is a tree of life medallion the client purchased. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477782188745-48N36GUR7QGVTKYM4UTD/IMG_1188.jpg Chester Springs Flitch Table A wider shot of the finished table and the completed kitchen nook. http://www.greengatewoodworks.com/hot-tub-to-garden-conversion daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975389781-N9YWRO18UUGHEAB82NU0/IMG_7555.JPG Hot Tub to Garden Conversion The clients I had built this ipe deck for a few years back, called up and told me their hot tub had finally died. They decided that instead of getting a new one, they wanted the space converted into a raised planter bed. Here is the hot tub shortly after I began cutting it up to remove it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975392753-BA9XTE5W6P8TBTO4YIFF/IMG_7630.JPG Hot Tub to Garden Conversion After removing the old hot tub and putting in some drainage lines, I framed up a new floor and side walls. I put down PVC sheets to line the bottom and then drilled holes through it to allow for water to flow through to the drainage lines. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975396991-HYPOT4RBO2LNQ0XMY357/IMG_7654.JPG Hot Tub to Garden Conversion After lining the interior with filter fabric, I applied ipe deck boards to the exterior and interior walls so that they would line up exactly with the existing decking. Over time, they will weather to the same silver color as the rest of the decking. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975399152-8L5G8CRG1L0U55AN0IOR/IMG_7656.JPG Hot Tub to Garden Conversion The last step for me was adding ipe deck boards across the top of the walls. After that, the landscapers brought in topsoil. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975400477-F206PYUOHV9RIE8FANFY/IMG_9973.JPG Hot Tub to Garden Conversion A few months later I was back on a rainy day and got this finished shot of the vegetable garden going strong. http://www.greengatewoodworks.com/wayne-garage daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087877562-OUJTS567FC8ODDJSJBQQ/Hanhausen+-+garage+-+walls+poured.JPG Wayne Garage A client came to us for a garage addition on their 1920's stone home. The job eventually expanded into including a patio and pool deck for a new pool they had installed while we were working with them. Here the garage foundation walls are going in. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087877513-YNIT3B6LDIOPFUSKNUUM/Hanhausen+-+garage+-+wall+framing18.JPG Wayne Garage First floor framing https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087868097-2IDCH23HN6KBWHOVT7U5/Hanhausen+-+garage++-+roof+sheathing.JPG Wayne Garage Roof framing and sheathing going on. A new hallway was created to allow access from the second floor of the home into the addition, which created a nice breezeway underneath. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087867000-J0GP1RO9IOJ2YKH78RSZ/Hanhausen+-+garage+-+crown+installation4.JPG Wayne Garage Doorway arches and exterior trim installation https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087875523-B26YGZUM12NVAF1HVF2M/Hanhausen+-+garage+-+stone+installation2.JPG Wayne Garage We took stone from the original house that was obtained during the second floor demolition to attach the addition and used it on the exterior of the new garage to help blend it into the original structure. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087878368-RRWM2184N5FA5XI8A37U/IMG_6604-A.jpg Wayne Garage Shot of the finished exterior https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087879352-KNR80YKZVE4ULLWDR729/IMG_6703.jpg Wayne Garage Stairwell from garage bays up to the second floor room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087866036-A4A222J4LE34JIZKAPDH/2nd+Floor-A+Pano-Flat.jpg Wayne Garage Finished interior of the upstairs room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087866089-CJ1OSARZ1DULU8UX7IF7/2nd+Floor-C+Pano+Perspective-flat+crop.jpg Wayne Garage Another shot of finished interior of upstairs room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087879360-OK9R9939KOJ99STHA7JW/IMG_6707.jpg Wayne Garage The upstairs room has a great view of the pool below. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087868918-8GRWFXYPG04NUOGI09PZ/Hanhausen+-+garage+-+fireplace+blockwork9.JPG Wayne Garage Construction of outdoor fireplace for future patio https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087870838-AJAZTQ9JGSNP4CWCCEZP/Hanhausen+-+garage+-+fireplace+blockwork12.JPG Wayne Garage Blockwork completed for outdoor fireplace https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087871335-H1RHC7BKF0FSUWR25GR9/Hanhausen+-+garage+-+fireplace+finished3.JPG Wayne Garage Here, the gas fireplace unit has been installed and stone has been applied to match the garage and house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087873108-1JQDL2MYPLE8BC9QICRK/Hanhausen+-+garage+-+retaining+wall+install17.JPG Wayne Garage The blockwork for the retaining wall is in place, which separates the lower patio from upper patio/pool deck. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087875323-SHFLE59MYHBXYD37YS4L/Hanhausen+-+garage+-+wall+finished4.JPG Wayne Garage Retaining wall completed with stone applied to match garage and house https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087878743-0KNLQXQ7XG408JKOA0DH/IMG_6617.jpg Wayne Garage Finished pool deck https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087878925-0YPGL3Q3UL2FJM75WGCN/IMG_6624.jpg Wayne Garage The finished pool deck and rear of garage http://www.greengatewoodworks.com/sofa-table-nesting-benches daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538982656-NKGXPQ651VQ8YK3UM0PT/IMG_8072.JPG Sofa Table & Nesting Benches A client was brought to me who had a number of old barn beams on their property. They wanted to make a simple sofa table with some nesting benches. JGM, Inc provided the bases for the benches and table. The barn wood was very rough initially, and it was delicate work to find a balance that made it pleasant to the touch without removing the patina of age the wood had acquired over the years. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538982735-7G1AZ7BXX4WUAOGPA51J/IMG_8074.JPG Sofa Table & Nesting Benches The benches store neatly underneath the table when not in use. Small furniture pads hidden under the feet ensure they are easy to move around. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538986801-S1Z4O6CALTG7MAPAQOPE/IMG_8077.JPG Sofa Table & Nesting Benches Side view of one of the benches where the original milling marks are clearly visible https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501538985716-6L1FIBEHPLWVUIHYSNQM/IMG_8082.JPG Sofa Table & Nesting Benches The character of the original beams is what makes this project really stand out. http://www.greengatewoodworks.com/havertown-kitchen-bath daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493515290564-QLZ3979WKSSG9NBDS0TH/IMG_0132.JPG Havertown Kitchen & Bath A client called me about this job after a pipe had burst while they were out of town. It had ruined their kitchen and a good chunk of their flooring in the adjacent rooms. Since the kitchen had to be replaced anyway, the client decided to use the opportunity to expand their kitchen into the attached one-car garage. During demolition, we discovered that the framing and subfloor under the second floor bathroom were rotten (unrelated to the kitchen leak), so that bathroom was gutted and redone also. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493515251584-AIUE9UV7E7IBDQW05P5I/IMG_0127.JPG Havertown Kitchen & Bath Before we arrived, the insurance company had already pulled up the flooring ruined by the leak. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087552192-V5FAHWYO3ZU1ULWDWDKX/IMG_9970.jpg Havertown Kitchen & Bath A custom set of built-in cabinets and window seat were requested by the client. We also installed prefinished hand scraped wood flooring throughout the first floor. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087552142-YCEW34GVNI0MQEHRHU0R/IMG_9973-A.jpg Havertown Kitchen & Bath We cut an arched doorway to provide access into the original one-car garage, which we converted into a living room and part of the new kitchen. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087553022-55Q5EI4QMF6DSCHSG12Z/IMG_9974.jpg Havertown Kitchen & Bath The new living room in what was once the garage https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087553074-XD8GKCU1IF5WN1HR3XG1/IMG_9990.jpg Havertown Kitchen & Bath The back half of the original garage space was converted into the new kitchen. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087553690-NMPSIVR056K39HKKU4VN/IMG_9996.jpg Havertown Kitchen & Bath A wider shot of the finished kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087553586-8V4VMHJ8KQ7PFNNZRN3W/IMG_9999.jpg Havertown Kitchen & Bath A new powder room just off the kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087551224-WG85CZBJ9LQ0M0S7H8M8/IMG_0004.jpg Havertown Kitchen & Bath Inside the new powder room http://www.greengatewoodworks.com/haverford-garden-door daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884762063-52TPTSMHXT80D79VWT84/IMG_0030.JPG Haverford Garden Door Client had a garden door inside a stone wall that divided the front and rear yards. It had become dilapidated over the years, so they asked me to build a new door to replicate it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884761986-CTJVT7DJZ69UVBNW84SB/IMG_0186.JPG Haverford Garden Door I picked up a bunch of rough white oak and got to work milling it smooth. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884769723-GVNHDPI0VJEINXCP5R23/IMG_0214.JPG Haverford Garden Door The curve at the top of the door had two different radii, so I had to do some math and set up an old school trammel to create the template I needed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884769794-D0KCQS7GRJ3MLNWZEBAY/IMG_0251.JPG Haverford Garden Door Gluing up the rear frame. It's held together with mortise and tenon joinery, and I used some temporary pocket screws to help hold it tight during clamping. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884775846-F7YJU226TRNKO244SK52/IMG_0256.JPG Haverford Garden Door Next I made up a tongue and groove blank for the front face of the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884777537-XO2ZPU6KJMESVSB3GSBN/IMG_0364.JPG Haverford Garden Door I fabricated all the parts in my shop necessary to make a true divided lite window, just like in the original door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884781693-1RQVDFQZ5H64AK2RO0AY/IMG_0405.JPG Haverford Garden Door After joining the two faces and sanding them down, I primed and painted the door to match the trim color of the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884784330-SI3VUJHG4Y9D1NBANR1H/IMG_0420.JPG Haverford Garden Door Out with the old and in the the new. I pulled the old door and transferred the hinges and hardware over to the new one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884791183-HTY9SN5812B1LHXAR92R/IMG_0459.JPG Haverford Garden Door The finished door as seen from the street. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884792254-38R35K273WTANQKDZKMU/IMG_0460.JPG Haverford Garden Door I also fabricated a new cross bar that was missing from the original door, so that the latch would be functional once again. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1510884796090-RMOOAYHMIEHOTI72FWE0/IMG_0476.JPG Haverford Garden Door Backyard view of the finished door. http://www.greengatewoodworks.com/havertown-window-seat daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491613257671-H5L1PKOSG7W84BCE10WE/IMG_9970.jpg Havertown Window Seat Part of a larger home remodel, this set of built-in cabinets and window seat features overlay raised panel doors, adjustable shelves, and custom moldings. http://www.greengatewoodworks.com/fathers-day-garden-sign daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974883950-LD6QU0OYY6LUJ0E6PS9F/IMG_2488.JPG Father's Day Garden Sign A friend commissioned me to make a sign for his father. Since it was going to be used outdoors, I made it out of ipe, a brazilian mahogany that will stand up to the elements. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974883333-8ZWCJN66FGJA9WY2J6ZV/IMG_2489.JPG Father's Day Garden Sign After deciding upon a font, I printed out this full scale version and used it to transfer the design to the board. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974886475-XNODDFQP3KRC2SRLU3DM/IMG_2493.JPG Father's Day Garden Sign After transferring the marks with a knife, I traced them with a sharpie for better visibility and began to remove material using a trim router. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974888274-FFO8K7R2BUHJNLEIY14Z/IMG_2495.JPG Father's Day Garden Sign Removing the material is a slow process, but not one you can rush. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974891132-MRQDH3QP24DO6AOWX6FU/IMG_2503.JPG Father's Day Garden Sign After removing all the material and cleaning it up a bit with a chisel and some sandpaper, it was ready to deliver. http://www.greengatewoodworks.com/barnwood-buffet-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605450203-VQAOE7FK2VOFNUY37NCW/IMG_8124.JPG Barnwood Buffet I was commissioned to make a buffet from some old barn beams I had obtained. I ended up using four of these pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605411600-VHP0VO0SRIIHCIA20H5W/Buffet-Barnwood+5-13-16+IMG_1646.jpg Barnwood Buffet Finished shot of the buffet https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605438358-27F9PNJ5NYML7CDQH3GL/Buffet-Barnwood+5-13-16+IMG_1653.jpg Barnwood Buffet Side view https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605433863-V6DUI0752P6RZXY2WSFY/Buffet-Barnwood+5-13-16+IMG_1659.jpg Barnwood Buffet Close up of the breadboard ends https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605443876-WAI900ZA261Q4U65M1DX/Buffet-Barnwood+5-13-16+IMG_1663.jpg Barnwood Buffet Looking down the dovetailed drawers. I had orignally picked out different drawer pulls, but when they arrived they didn't have the feel I wanted. I opted for larger, heavier pulls that worked better for this piece. Little details can make a big impact on a project like this. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605420421-TOTX9V63CS6A5Y0DC486/Buffet-Barnwood+5-13-16+IMG_1638-36-flat.jpg Barnwood Buffet Shot of the finished buffet before being delivered to the client's home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477605531972-T9XGCZPBGTAQT9U0Z3PX/IMG_9524.JPG Barnwood Buffet Picture of the photo shoot with Flip Krugler. Pogo the Supervisor Cat keeps an eye on things. http://www.greengatewoodworks.com/barn-beam-mantle daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838114358-Z81AEZ28PL3MHRU7R43E/IMG_6397.JPG Barn Beam Mantle Clients of mine requested a barn beam mantle for their new home, so we took a trip to the sawmill and picked out on they liked. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838116354-AY6PJB9DG88XD5UADNY1/IMG_6399.JPG Barn Beam Mantle I cleaned up the back side of the beam with my router sled for ease of installation. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838113916-XT7OWF0YIT666D28NCYZ/IMG_2501.JPG Barn Beam Mantle The installed mantle. I used a thin epoxy to secure some weakened areas on the beam and finished it with lacquer. They both soaked into the wood giving it a deep, rich color without using any stain. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838111710-A4QZZ0RVAZRLUWTMK4OA/IMG_2480.JPG Barn Beam Mantle Looking down the face of the mantle https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478838111973-6D3ZYF9I88NB0NW0XFSG/IMG_2478.JPG Barn Beam Mantle The marks where the beam was originally hewn by hand are still visible. http://www.greengatewoodworks.com/lohr-arts-crafts-table daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613425321-1W2FQFFOIRJZEI90KJR8/Jeff+Lohr+2nd+level+class+product+oiled+2.JPG Lohr Arts & Crafts Table An Arts and Crafts style table I did as part of a furniture making course I took. The course was run by Jeff Lohr (http://www.jdlohrwood.com/), and I highly recommend it if you have an interest in that sort of thing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613427400-7HKHELUM79DBDMSFNUXR/Jeff+Lohr+2nd+level+class+product+oiled.JPG Lohr Arts & Crafts Table http://www.greengatewoodworks.com/reclaimed-farmhouse-table daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606972936-RHMF8BMWZROPZM8R66IC/IMG_4835.JPG Reclaimed Farmhouse Table I was commissioned by an existing client to create a dining table for her daughter. They wanted to use reclaimed materials, so I looked around and came across these joists that were pulled out of a 1920's home and were set to be thrown away. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606961670-TOIM89JIZG3L2G8NVM42/IMG_0446.jpg Reclaimed Farmhouse Table After removing many, many nails and cleaning up the original boards, I turned them into this farmhouse table. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606960239-72MLA0SEHZ9CP4U5CU03/IMG_0424.jpg Reclaimed Farmhouse Table Measuring approximately 38" across and 78" long, the table seats 6 comfortably. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606962796-4TS36JB5QVV1T8HDGNCZ/IMG_0470.jpg Reclaimed Farmhouse Table The breadboard ends on the table help to keep the tabletop flat while still allowing it to expand and contract with seasonal changes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606958223-Z9J7YFC1NJJMV1U25BZY/IMG_0385.jpg Reclaimed Farmhouse Table I fabricated and installed these black walnut butterfly keys, also known as Dutchmen, to secure a crack in one of the boards and keep it from growing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606963609-Z8V0BHB48RYFLQ2YJOHC/IMG_0474.jpg Reclaimed Farmhouse Table A slight taper to the legs gives them a little visual interest and reduces the visual weight of the legs so they don't overwhelm the overall design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606961077-LTDI32D6OG61C84UESTB/IMG_0447-crop2.jpg Reclaimed Farmhouse Table I chamfered the corners of the legs for an additional detail. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477606962925-RH8QQRWGHFI5EB25GS6Q/IMG_0448.jpg Reclaimed Farmhouse Table Finished shot of the completed table https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477607038652-Z3DQDG2AIB5ZWHCCD4Z7/Victoria+murray+and+her+table%2C+delivered.jpeg Reclaimed Farmhouse Table My clients (the recipient's parents) delivered the table to their daughter in Massachusetts and sent me this picture of her and her fiancé with the table in its new home. http://www.greengatewoodworks.com/philadelphia-ipe-deck daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087525313-PUWDFADH8DDHDO0KTQ8Y/murray+before+panorama+big.jpg Philadelphia Ipe Deck This was a deck project I completed back in late 2009 - early 2010. This is a before shot of the original deck. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087375949-AZSO7QAQG71IATVEP492/IMG_4877.JPG Philadelphia Ipe Deck We installed new footings and a pad to elevate the original hot tub up into the new deck. Then we began to install the framing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087394726-HJFSIYSMNGGI3L3CT2SW/IMG_4982.JPG Philadelphia Ipe Deck Installing the large main beams for the pergola https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087400562-SOT3OG2N0JET9PDHXBS6/IMG_5148.JPG Philadelphia Ipe Deck All the trim work on the deck was made of ipe, as shown here on the post wrap details. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087387771-TEDXOWU9CQP68OG2UKZ1/IMG_4938.JPG Philadelphia Ipe Deck Framing for the main deck stairs https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087416343-YDKD9SEPKLHAM65SEIY0/IMG_5319.JPG Philadelphia Ipe Deck Main deck stairs with ipe decking installed https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087479446-0QGV0569TVM2FO0YV3SY/IMG_6953.jpg Philadelphia Ipe Deck Wide shot of the completed project https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087451276-98WKNHLUQDQODLO2HXGI/IMG_6940.jpg Philadelphia Ipe Deck The hot tub surrounded by the new decking. The tub sits up above the decking approximately 20" so that it's easy to sit on and turn to drop right in. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087470956-7I8533FVQRD2GJVUAWAG/IMG_6943.jpg Philadelphia Ipe Deck Looking down towards the far end of the deck from the hot tub https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087501435-9MQV53S6N6SFHV5V46O7/IMG_6971.jpg Philadelphia Ipe Deck In the original deck there was a flagstone patio that the client wanted to keep, so we stripped the original flagstone off and reset new stones. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087449255-6JH00VIRB4Y92A2PU9DN/IMG_6937.jpg Philadelphia Ipe Deck Shot of the outdoor kitchen area. Originally it was intended to have cabinets and stone countertops, but the client decided to hold off on those finishes for the time being. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087491000-6NYLMTN5SMNVX46P2SZK/IMG_6954.jpg Philadelphia Ipe Deck The main staircase and pergola https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087519495-NX0IYCSGXD0VDMFOREO6/Steps-2-CD.jpg Philadelphia Ipe Deck The pergola has a retractable canopy on it to provide shade from the summer sun. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087390241-8I4994G4U5ZTX6X8JG3B/HouseView_6925-6.jpg Philadelphia Ipe Deck The lower flagstone terrace https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087431539-K8L65DJPAWLWRQ30E89N/IMG_6919.jpg Philadelphia Ipe Deck Finished shot of the right side of the deck and terrace http://www.greengatewoodworks.com/chester-springs-nook-bench daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084214276-594EPT7K8HPZ0UVSA72N/IMG_1250.jpg Chester Springs Nook Bench Part of a larger kitchen nook project, I created this built-in bench and finished it with white chalk paint and antiqued it with a mix of dark and clear wax. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084214317-TY5U9KBIOG851P1EPD56/IMG_1253.jpg Chester Springs Nook Bench The bench top lifts up to reveal additional storage space inside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084213588-ND53DU00XTO8A2K7BHNK/IMG_1197.jpg Chester Springs Nook Bench The client had custom cushions made for the bench tops, shown here alongside the live edge white oak table I made as part of the overall project. http://www.greengatewoodworks.com/haverford-builtins daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084679860-F5DJ1E35GH95SCZVLNJ5/Haverford+9-2015++IMG_1044.JPG Haverford Built-ins A long time client had moved and wanted some built-ins to provide additional storage in their new home. This unit is one of a matching pair in their living room, with the other one being on the far side of the room. Two other units are in a front room of the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084674316-L6E4SRKQN09GYH2D3W1O/Haverford+9-2015++IMG_1045.jpg Haverford Built-ins Close up shot of the living room lower cabinets. Both pairs of built-ins in this room have inset flat panel doors and oil rubbed bronze hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084679312-KZZIU5MORCAW4U4YESWK/Haverford+9-2015++IMG_1049.JPG Haverford Built-ins Finished living room units, right side. Two fixed shelves were included on each of these back room units to accomodate the weight of the client's vinyl record collection. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084686279-HHUS5658OWVAJBJJKN32/Haverford+9-2015++IMG_1056.JPG Haverford Built-ins This pair of cabinets sits in the front room of the house. They also feature inset flat panel doors and oil rubbed bronze hardware. Each unit flanking the fireplace has an existing recessed overhead light incorporated into it. The client installed a wirelessly controlled LED bulb in each one that allows the color of the light to be adjusted via a smartphone. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084681454-03I2O04NY1G3VRNQWJ7M/Haverford+9-2015++IMG_1056-btm.jpg Haverford Built-ins The front room units incorporated high baseboards to tie them into the existing trim scheme. http://www.greengatewoodworks.com/kids-art-desks-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614497152-V1FYBQPY0Y4ZLIRRFJ2Y/IMG_7855.JPG Kids' Art Desks I made a pair of these kid's art desks as gifts for my cousins' kids based on a design I saw online. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614497946-O3XHE2FOA7C132XK3TRN/IMG_7856.JPG Kids' Art Desks The top lifts up and are secured at various angles with a brace attached to the underside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614510905-W06YOK0C5R73AC7NRBZR/IMG_7870.JPG Kids' Art Desks Each desk has a small drawer for storage. The white T-shaped dowels set in the desktop slot keep papers and pens from sliding off the desk while it's raised. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614503859-U0E5B8VG6GMIEI7EHCQZ/IMG_7863.JPG Kids' Art Desks Both desks can be raised up as the kids grow to provide years of usefulness. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614507000-IMI429503QGLKMZXRER9/IMG_7867.JPG Kids' Art Desks Another shot of the completed desk http://www.greengatewoodworks.com/reclaimed-flooring-picture-frames daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975259834-4JVFHRJMB1907TGY6V19/IMG_8814.JPG Reclaimed Flooring Picture Frames Picture frames I made from reclaimed flooring. I made four standard sizes: 3x5, 4x6, 8x11, and 11x14. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975253451-HZMHNTWBIW6GAZZ4B1B0/4x6+back+bright.jpg Reclaimed Flooring Picture Frames Hardware on the back of each frame allows for hanging it in either direction. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975253581-PAN9W0PU0AB2NE8MSEQ0/4x6+detail+bright.jpg Reclaimed Flooring Picture Frames The original cut nails in the floor were left for visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478975257070-FAN1VBXA3KAXFZCP56XB/IMG_1749.JPG Reclaimed Flooring Picture Frames Close up shot of the mitered corner and another flooring nail https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496883125911-SC4AMP9O6GRWI817FIBU/Gillian+picture+in+reclaimed+frame.jpg Reclaimed Flooring Picture Frames I kept one frame for myself to hang some artwork my daughter made in nursery school. http://www.greengatewoodworks.com/tommys-lunchbox-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508549219507-MB9AOYQP2I6DWT8WDBRS/IMG_5168.jpg Tommy's Lunchbox Sometimes my custom solutions aren't just for my clients. Tommy, my helper, came to work one day without a lunch box, so I quickly made up one for him out of an old Milwaukee drill case. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508549219419-ONMRFEFVB74RF733B9VL/IMG_5169.jpg Tommy's Lunchbox It took about 5 minutes to cut out the molded insides of the case and open up a lot more usable space. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508549220512-1WNTGPYXR4RLIS5OI4TE/IMG_5170.jpg Tommy's Lunchbox Tommy is pleased with the result. http://www.greengatewoodworks.com/africa-yew-slab-table-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496189600-C2WKQAR27G4RWKHETWR3/IMG_3927.JPG Africa Yew Slab Table A client had a large yew bush cut down on their property and brought me a slab from the stump to use for an outdoor table. Since it was freshly cut, it had to dry for a year or so on my racks before it was ready for use. After it had dried, I put it on my router sled and flattened it out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496194124-TO4EV0TULQM05SIMXIUS/IMG_4007.JPG Africa Yew Slab Table Using a chisel, I carefully removed all the bark from the slab to reveal the beautiful live edge underneath. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496192755-2YBYOZEQMW8Z0X4GA2AD/IMG_6191.JPG Africa Yew Slab Table I designed this simple metal base for the table and my friend John Parker of The Painted Garden, Inc fabricated it for me. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496284871-LIOEZTPDBBRZG0MNEML1/IMG_4210.JPG Africa Yew Slab Table After it was sanded completely smooth and had many coats of spar urethane applied, the table was ready for use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496190714-37WR136JZDNI4F5XIOXQ/IMG_4278.jpg Africa Yew Slab Table Outside in the sun, the colors really come to life. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496191221-5R2VPRL35XD28EVPC6JY/IMG_4279.jpg Africa Yew Slab Table Looking down the live edge. The creamy white of the sapwood contrasts beautifully with the red heartwood of this yew slab. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1508496192126-UG0PCW86KM1K0BSIX8FF/IMG_4280.jpg Africa Yew Slab Table Looking straight down at the top, it's easy to see why I call this piece the "Africa Yew Table." http://www.greengatewoodworks.com/devon-adirondack-chair daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517306760-N4IUDAY54BPVPIHSQNPT/FullSizeRender-2.jpg Devon Adirondack Chair I was working on a different job for a client when they mentioned their adirondack chair had been broken and asked me to look at it. It was damaged beyond repair, so I offered to make them a new one based on some templates I had made up a few years back. Since they were having a party coming up a few days later, I got to work immediately. Here the individual parts have been cut out and primed, and are drying in the back of my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517307034-YLJC2I0LUUE27DZW3H38/FullSizeRender.jpg Devon Adirondack Chair I assemble the chair in four sections - two arms, one back, and one base - in jigs I made up specifically for that task. Here, the four sections are assembled and painted the final color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517306806-0NBRLSIMHVI56BM9KIVS/FullSizeRender-1.jpg Devon Adirondack Chair I managed to get the chair fully assembled, touched up and delivered the morning of their party. The design of this chair is very inviting and so comfortable, you never want to get up again. http://www.greengatewoodworks.com/green-gate-sign daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974765844-QCU7PZNXJ7G20VZH6PGX/IMG_7944.JPG Green Gate Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974766474-PD0JNEXQRNGEWHAFVX19/IMG_7946.JPG Green Gate Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974767795-9BSS27OSSQZ7B815NIRA/IMG_7947.JPG Green Gate Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974768557-8BPXWYS4TDV49W9WPFY9/IMG_7952.JPG Green Gate Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974770414-WV0TG2V84PA0RK6APDS2/IMG_7962.JPG Green Gate Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974771141-FSAUBQIFF2Q5UL91KWIW/IMG_7963.JPG Green Gate Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974774249-YXXOYKC27C80EXBZK86N/IMG_7976.JPG Green Gate Sign https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478974774960-BYKENYKLU6YEX4LT9H1K/IMG_7977.JPG Green Gate Sign http://www.greengatewoodworks.com/toy-truck-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973403774-ZI3T1W8UH8BXUEYMKQMS/Will+Krugler+truck+project+-+before+2.JPG Toy Truck When my nephew came along I had already made a crib for his sister, so I decided to make a toy truck for him. I found this design in a book on toy building. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973411768-Y39PNDN42Y7H5HFN688K/Will+Krugler+truck+project+-+cab.JPG Toy Truck The cab of the truck shaped out of alder https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973401417-88GOKTK4UBIL8PD6JR68/Will+Krugler+truck+project+-+bed+and+cab+on+chassis+3.JPG Toy Truck I used some ipe scraps from another job to make the wheel wells. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973400008-LASGPUO3VLPH91ZV434G/Will+Krugler+truck+project+-+axle+frames+on+chassis.JPG Toy Truck With some more alder and a few small dowels, the details began to take shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973422137-5Z4JSSKVC52TPWAU0MQW/Will+Krugler+truck+project+-+finished+5.JPG Toy Truck The completed truck, finished with several coats of boiled linseed oil. The wheels, like the wheel wells, are made of ipe. http://www.greengatewoodworks.com/my-distressed-flooring daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837833618-1EOLU07PS7RS1MNM1V2L/IMG_8198.JPG My Distressed Flooring While my own house was under construction I lived with a mish-mash of old oak floors, plywood patches, and ancient linoleum for a few years before I was ready to install new floors. Here you can see the old oak flooring piled up after demolition. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837835390-S4375CBXA610EZ1YPCU0/IMG_8235.JPG My Distressed Flooring After the old floors had been removed, new 8" wide red pine floors were installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837836413-TPE0JGNOP8YT2FTS4CQ6/IMG_8245.JPG My Distressed Flooring New floors in the dining room and office. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837836874-5PI3OH4W0S0US03TMHKG/IMG_8264.JPG My Distressed Flooring New floors being installed in the kitchen and living room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837838324-LKAN2EPIBKCQ647AMCPV/IMG_8282.JPG My Distressed Flooring To get the antique look we wanted, I hammered in masonry cut nails through the face of the planks. It ended up being 2,420 nails (63 lbs worth). It'll be a few years until I forget how bad it was and agree to put new floors in upstairs. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837842173-2NQVEWG5S3QRJXUNTMXZ/IMG_8318.JPG My Distressed Flooring After sanding I applied a preconditioner. This helps even out the color of the stain when it goes down. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478837843794-BH79BH881P2ROLW1ED8M/IMG_8404.JPG My Distressed Flooring After staining and a few coats of polyurethane, the floors were finished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770942291319-DX66GQ4GA99AVHFHGWMW/IMG_8814.JPG My Distressed Flooring Instead of trashing all the original flooring from our house, I took some of it and turned it into these picture frames. http://www.greengatewoodworks.com/painted-oak-granite-table-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477781829653-THSJNML6G4KJVR2DL4LO/Monica+and+Gary+Cummins+table+project+-+finished+table+2.JPG Painted Oak & Granite Table A small kitchen table I made for my neighbors. They had an extra slab of granite left over from their kitchen renovation and wanted to turn it into a table that would match their existing dining room table. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477781831823-TKBQAXMI5T2405OG6WX7/Monica+and+Gary+Cummins+table+project+-+finished+table.JPG Painted Oak & Granite Table Another shot of the table with slightly better lighting http://www.greengatewoodworks.com/berwyn-ipe-deck daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519910569-3GUH6FFVCV2JLJ8BI9ZU/IMG_2480.JPG Berwyn Ipe Deck This client wanted to get rid of the rear staircase that was left over from construction on their home. I worked with them on developing a design for a small ipe deck to provide a landing area outside their doors. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519910489-91WR271ZTU5V2UM73MQL/IMG_2493.JPG Berwyn Ipe Deck The main framing is installed. The open framing at the corners is where the steps will curve around. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519540363-IZ15GKQYFR4UJLE239NE/stephanie+ipe+deck+3.jpg Berwyn Ipe Deck These are the curved risers for the stairs that I made for the deck out of ipe and pressure treated framing lumber. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519913195-FVINKGX4UVQ6EDFVNGW0/IMG_2572.JPG Berwyn Ipe Deck Here, the risers and necessary framing have been installed, and I'm starting to install the decking. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519540041-BRHYI2M40O2J97MA2YRA/stephanie+deck+2.jpg Berwyn Ipe Deck The upper stair tread also serves as a border for the main area of decking. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501519542284-W1GJHW6T65XEBUE03GGL/stephanie+ipe+deck+1.jpg Berwyn Ipe Deck The finished product with post wraps and railings installed. http://www.greengatewoodworks.com/black-walnut-crib-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613630477-UIE4B7ZQXACXADRTM8NU/IMG_2325.JPG Black Walnut Crib When my daughter came along I decided to make a crib for her, so I went and picked up some walnut from the mill and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613628266-ZL431337SG3495GT9RO6/Gillian%27s+Crib+12-8-13_IMG_9774.JPG Black Walnut Crib The finished crib in her nursery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613627778-8C1OQHFI4YH0ZDPIEW1U/Gillian%27s+Crib+12-8-13_IMG_9776+cropped.jpeg Black Walnut Crib Another shot of the finished crib https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477613641638-OLAGYD88K0HJZL0NHMNT/IMG_3510.JPG Black Walnut Crib The satisfied client http://www.greengatewoodworks.com/rocket-ship-bed daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477779768312-X5LTOY3ITEWSK70Y69NB/IMG_3867.JPG Rocket Ship Bed I received a call from a client who wanted a rocket ship bed made for her son's birthday. She provided a picture of what she was looking for, so I scaled up some drawings. In this picture is one of the sides of the bed, cut out and shaped. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477779772855-8PLIKM47D6ZC94ZVIRR5/IMG_3873.JPG Rocket Ship Bed Side view of the assembled bed with the portholes cut out and installed. The client wanted to paint the bed herself to save on cost, so I delivered the product unfinished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477779771593-AE1GPRC8SMXG1YCTYTL8/rocket+bed+collage.jpeg Rocket Ship Bed The finished product in place and ready to use. The client did a great job painting, and the bright colors really bring it to life. http://www.greengatewoodworks.com/leprechaun-door-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496880512429-XS2MGVH10JDQERK0OXWZ/119.JPG Leprechaun Door I found a request from a person in an online woodworking forum looking for a "leprechaun door" to install as a creative patch to a hole in their wall. Seemed like an interesting project, so after we worked out a deal for it, I got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496880529019-SZAFDNQ8T2F1UFQ2QUOB/IMG_3881.JPG Leprechaun Door Front shot of the leprechaun door. I built it out of some scrap poplar and plywood I had laying around the shop. Overall it's about 6" wide by 11" tall by 3" deep to fit inside their wall cavity. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477659944692-HRUY6V2EP287CCVADEH0/IMG_3884.JPG Leprechaun Door I shipped the door out unfinished so the client could paint it and add their own hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496880523208-ENKCDS4N4AXKQIRMK5JV/132.JPG Leprechaun Door I received this photo back from the client of the finished and installed door. It was a fun little project - took about three hours to complete - and I got a nice original painting in return for my daughter's room. http://www.greengatewoodworks.com/devon-staircase-rehab daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517733838-RPWAG6L80ZTZ6QJ5FAW0/Milines+before+stairs.jpg Devon Staircase Rehab This job came to me from a client who was having a wedding reception at their home and were concerned about their existing staircase. The treads and risers had rotted out over the years and needed to be replaced. I suggested ipe for the job for its durability and rot-resistance. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501517733916-MX1OBLBA7EMTF2H2Q3BS/Milnes+after+stairs.jpg Devon Staircase Rehab The finished job with all treads and risers replaced with solid ipe. Hidden fasteners secure the ipe to the framing below, and where the fasteners wouldn't work I used ipe plugs to conceal stainless steel screws. After sanding them flush they disappear into the overall design. http://www.greengatewoodworks.com/shop-renovation daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087796581-EOKT05GPSDTRQ52O77R4/Murray+Shop+renovation+-+before.JPG Shop Renovation This job came from a client I had done some work for previously. He had a small shop in his basement where he liked to work on various projects, but it was cluttered, lacking in storage and outlets, and not bright enough, so he asked me to renovate it and make it more functional. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087794056-T3NLNAG2QCIKP7VKSATU/Murray+Shop+renovation+-+before+4.JPG Shop Renovation Here is another before shot of the original workshop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087794696-LCKHZR5H2J16N011IEHJ/Murray+Shop+renovation+-+before+7.JPG Shop Renovation One more for good measure https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087785501-D2YVY0C2839NW5NMFBYZ/IMG_9932.jpg Shop Renovation The renovated shop. I replaced the existing windows, packed out all the walls to add electrical outlets, built a dust vacuum system to aid in clean up, and added six new light fixtures. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087785159-OARSWYC5VDI1FVYFMQ6M/IMG_9933.jpg Shop Renovation I added slatwall panels to the upper portion of all the walls to create more hanging storage for tools. I also added new baseboard heaters and custom cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087785613-W5RV1VRDBS3A7K5NUYBZ/IMG_9937+CornerDoorClosed.jpg Shop Renovation I built this tall cabinet and corner shelf unit along with the countertop to create usable space around the existing file cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087785750-LCEXIUKUTK08RO96UN8G/IMG_9937+CornerDoorOpen.jpg Shop Renovation The tall cabinet opens to reveal a number of small drawers for housing small boxes of screws, nails, and other hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087786614-H0AQO4XUNBH83G3UP46H/IMG_9940.jpg Shop Renovation The dust vacuum system is housed beneath the long custom countertop by the window. The end cap of the system is removable to attach a vacuum hose for cleaning the shop floor. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087787766-QO2AX24KO4O4K9UFWW58/IMG_9943.jpg Shop Renovation Each machine has its own dust port with a blast gate that closes it off when not in use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087790221-UGVMJNTAT8B2GB05JCE3/IMG_9945.jpg Shop Renovation I designed and built these custom maple cabinets with plexiglass door panels to allow the client to see the items stored within. The floor was painted with a epoxy based garage floor paint to create an easily cleaned and stain resistant surface. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087792365-LWUCMITZDUQQBPH2YPSC/IMG_99550+LargeDoorTotalOpen.jpg Shop Renovation The tall wall cabinet provides storage for longer items like clamps and sections of pipe. All the pulls and handles on the cabinet doors and drawers are in a weathered bronze finish. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087791128-JBBVKCZ9J3QKJA9YQH2H/IMG_99550+AllDoorsClosed.jpg Shop Renovation The three doors next to the wide cabinet door are a raised panel bi-fold door system I designed and created specifically for this job. They provide access to a water shutoff and pressure relief system while not eating up unnecessary floor space. A video of them in operation can be seen at the end of this gallery. http://www.greengatewoodworks.com/treadle-base-side-table-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614851379-556KWRPZH38K338A5VDO/IMG_4800.JPG Treadle Base Side Table A client asked me to make a table top for an antique treadle base. She wanted to use reclaimed lumber, so we took a trip to the architectural salvage yard and found a bundle of old tongue-and-groove flooring. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614859048-R52T66YMUBF2MBVXIB29/IMG_4852.JPG Treadle Base Side Table Shot of the finished table. After milling the wood it had lost some of it's darker character, so I used a blowtorch to bring it back and then sealed it with several coats of lacquer. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614858164-GKD0X9LPSZVQ103E23BQ/IMG_4857.JPG Treadle Base Side Table A shot showing some of the details of the treadle base https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477614862928-T3D2G6M0IA3C7M0FLA9F/IMG_4858.JPG Treadle Base Side Table Side shot of the finished table http://www.greengatewoodworks.com/painted-oak-crib-1 daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615765475-1633X4MT3VFRCFOKAKSW/CIMG0049.jpg Painted Oak Crib When I found out my niece was on the way, I wanted to make a crib for her. My brother-in-law and his wife showed me a design they liked, and I replicated it in red oak. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615767553-3BQ9IAY2IYGDX3G6567K/CIMG0058.jpg Painted Oak Crib Here, the curved top rail for the back wall of the crib is clamped up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493239505132-814JB76CWIYMQ86LGADO/IMG_0123.JPG Painted Oak Crib The finished crib delivered to her nursery https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1493239527693-D8DVUU1I2CBNWNHZWEDA/IMG_0124.JPG Painted Oak Crib Closer shot of the finished crib. Since she grew out of it, it's been used by her two younger siblings. http://www.greengatewoodworks.com/adirondack-chairs daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615000809-8IJXDQBGHK2DB3FPNMYN/best_chairs+in+yard_profile_turk+daisy.jpg Adirondack Chairs My dogs hanging around a set of adirondack chairs I made. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615000881-R0GFFSPEXK7H475BX9TL/best_chairs+in+yard3.jpg Adirondack Chairs Looking out over my back field https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477615007984-DB4Y54ZNOJKVZ63NZNP0/little+chair+unpainted.JPG Adirondack Chairs I made a half scale version of the chairs as a gift for some friends. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496864921881-5AYKELZHHTPUUHROD8US/baby+andy+in+little+chair.JPG Adirondack Chairs The half scale chair and its future occupant. http://www.greengatewoodworks.com/my-house daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501514216692-7JNNQX4UNFQJROYRX9EH/O6ESY8W+-+Imgur.jpg My House This gallery shows some aspects of my ongoing personal home renovation. In this writeup I’ll include pictures of various rooms throughout our home with links to galleries specific to each project. Here is the original rancher we started with, which was a kit house built around 1954. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591453033170-Q1QU6GM4NTZ2LRVU6QP5/0AAE11CC-FE08-4E74-B94F-B6B347D7C193.JPG My House The house as it currently stands (June 2020). Our goal is to make it look like a 19th century stone farmhouse that would have been original to the area. We removed the original porch on the left side and turned that into living space, then added a partial second floor. The remaining 8' or so of the first floor was then shifted to the back edge of the foundation wall to create the offset look of an addition. The main center area of the house has Chester County fieldstone applied all the way around, while the remaining areas have cement board siding. I collected the stone for house by hand from neighboring properties, then had it cut down into veneer stone before it was applied by L.S. Stone Masonry. Luis and his crew did a fantastic job and I highly recommend them if you’re looking for a mason. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591453033551-CRJWADT97V1TFTWUA8ED/B5F74F19-6CC8-49AB-B027-30313B39CFAF.JPG My House Along the driveway are the three rooms we created in place of the original porch. From back to front there is a mudroom, laundry room, and greenhouse. Above those rooms and wrapping around the back of the house is a roof deck accessible from the master bedroom, with a custom railing made by JGM, Inc. Rope lighting on the roof deck and inside the ceiling of the rear covered porch provide the perfect amount of light for sitting outside on warm summer evenings. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770904722317-EW557ZZCGH80MAOZUO0R/IMG_0665+2.jpeg My House This is our mudroom, the first of the three “porch rooms” as you enter. In keeping with the feel of the original porch that was there, I installed reclaimed brick floors and a v-groove wainscoting ceiling. More pictures of this room build can be seen here. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905280715-H4C3N7Q2YMLJ6TSU0GIO/IMG_0701+2.jpeg My House Our mudroom lockers include a black walnut bench, custom crates up top for smaller items, and true Penco brand locker numbers. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770904915199-ZJMY9WPPI5UOHEHZ41SC/C3C15908-CC58-49FA-980B-F22CAF904B85.JPG-2.webp My House Our laundry room, just off the mudroom, has a black walnut countertop, large farm sink, custom cabinetry throughout, and a hidden laundry chute. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906941652-324ZRUN30VFXHP7AI01N/C592B8E8-5EEB-4629-A57D-82D75FB72CCC.JPG.webp My House The last of the three porch rooms is our sunroom that we call the greenhouse. In addition to the reclaimed brick floors and wainscot ceiling, it has stone to match the exterior of the house, custom paneling, and, naturally, plenty of plants. Ducts coming from and returning to the main section of the house allow this room to act as a passive heater, circulating warm air through the home with no moving parts. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501521603996-WOIM3P6K9Y3533RLB4WU/1217+kitchen.jpg My House Moving on to the kitchen, I made all the cabinets, doors, and drawers in my shop. Eventually there will be a peninsula along side the last cabinet on the right which will have a butcher block top and will serve as a prep area for when I cook. The countertops in the picture are temporary plywood ones. I milled rough lumber from a maple tree on our property and will turn that into wood countertops once it is dry, which should be sometime in mid-2018. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905178866-T468KJ74TZIGTP3E3KMA/Campbell%2BBuilt-In%2B2-2019%2BIMG_4507%2B-%2Blightened%2Bfloor%2Bfixed.jpg.webp My House Beyond the kitchen is our living room. I installed these built-ins as a Christmas present for my wife. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770942145055-9XZLNN4GOIWRJWOVOTDC/Screenshot+2026-02-12+at+7.20.44%E2%80%AFPM+2.png My House I installed this distressed red pine flooring throughout the first and second floors of my home to keep with the 19th century character we were going for. Red pine was widely available at the time and used in many older homes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905178786-7XD9ECKJSL223A1YZFKD/1217%2Bgirls%2Bbulit-ins3.JPG.webp My House Upstairs I installed these built-ins in my daughters’ room. Dutch the cat is a big fan of the window seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905179914-RC4NOI9PLW07A6W7N95D/IMG_8889.JPG.webp My House When my youngest daughter was born, my wife asked for a sliding window cover for her nursery. I built this using some extra wood in the shop and fabricated the hardware myself as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501521604189-CTA62GUK6JG9MT8BJ742/1217+window+trim.jpg My House Just before Christmas 2016 I installed window trim throughout the house. In this picture they still need nail holes filled and a coat of paint, but now that we had windowsills we could finally use our electric window candles for the holidays. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606146631372-EJDPWV1USA96LJX58TIR/IMG_1603.jpg My House An outside shot of all the window candles turned on. I installed outlets at each window that are hooked to a single circuit in what's known as a "holiday package." This circuit is controlled by a mechanical switch which turns them on and off automatically, along with our christmas tree lights, christmas wreaths up in the cupola windows, and a second christmas tree in the greenhouse. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770905179873-4BYZRHPH8D5QZGL4ADMK/IMG_1483.JPG.webp My House For a side project, I also created this LEGO scale model of the house for my kids. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770908357191-NWEDCY0RIAX2QNEQPKVZ/IMG_1267.jpeg My House In addition to the house renovation, I also built a new workshop on my property. http://www.greengatewoodworks.com/daughters-bedroom daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491615717452-ALVCVRMDF1U865B5T163/IMG_8889.JPG Daughter's Bedroom As part of my on-going personal home renovation, I made this sliding barn door window covering during the nursery preparation for my youngest daughter, The pre-made hardware at the store was outside my budget, so I made my own custom track and hangers in the shop. http://www.greengatewoodworks.com/haverford-kitchen-table-banquette daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503366-ORIWYH2Z1FOVGXNR8DJE/sold+1.jpg Haverford Kitchen Table & Banquette A kitchen table and built-in banquette project I completed for an existing client. The table is 46” square with a 2-1/2” thick solid rock maple top and a simple pedestal base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503410-IQY8F6OJICXYSQKYULF5/Sold+2.jpg Haverford Kitchen Table & Banquette The all-white banquette base and back provide contrast to the black table base, while the matching bench tops and table top tie the two pieces together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503533-HV02NAB30E54EJDYYANZ/Sold+3.jpg Haverford Kitchen Table & Banquette The area for this breakfast nook was small, and the client had a concern about how close it would be to their existing kitchen island. I gave the table two 7” wings that fold under and lock into place to reduce its overall size when not in use. Furniture pads hidden on the bottom of the pedestal base make it a breeze to slide the table in closer to the banquette to gain more space when necessary. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503579-J0M8ZURII4NOGQPMSD1U/Sold+4.jpg Haverford Kitchen Table & Banquette The bench tops have concealed Soss hinges and open up for additional storage space inside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1501515503664-EK690MFCGYE15KC7FV9B/Sold+5.jpg Haverford Kitchen Table & Banquette The banquette has solid rock maple tops to match the table, and a simple flat panel design on the base and back to match existing paneling in the house. At the far right side there is a recessed shelf that houses two outlets and provides an area to hide away phone chargers, etc. http://www.greengatewoodworks.com/manayunk-kitchen daily 0.75 2018-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087663947-OJ0F9BDCIHR1WVD5AU0B/ali+c+panorama+1.jpeg Manayunk Kitchen This job came to me from a client with a very cramped kitchen who was looking to renovate and expand a bit. This is one of the before shots. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087663992-G3ENAAKJ5LD9IHHDC3OE/Ali+C+panorama+2.jpeg Manayunk Kitchen Another before shot of the kitchen https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087664430-J7N22XN1AOLC5O5LQ0WG/GreenGate-ManKitPano-2flat.jpg Manayunk Kitchen Wide angle shot of the new kitchen, showing the wine fridge in center island. We opened the wall up between the kitchen and dining room to allow for more light, better airflow, and to create a breakfast bar for casual dining. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087664709-CKO0UHIU5Y5FKH9SWBDJ/GreenGateIMG_6046.jpg Manayunk Kitchen Bamboo countertops https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087664979-5Q0SHNA93RIG3MD986ZR/GreenGateIMG_6052.jpg Manayunk Kitchen New cabinetry, counters, and appliances https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087665161-ZE3IS5BFY21F3ME9PEQL/GreenGateIMG_60201026.jpg Manayunk Kitchen Sink countertop and opening to dining room https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087665558-7NZWE4XXAAISI3U5OJNB/GreenGateIMG_60301026.jpg Manayunk Kitchen Teak drainboard next to sink for drying dishes https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087665753-KPUS8ZDY8BBTE0Z0I7IV/GreenGateIMG_60321026.jpg Manayunk Kitchen The recessed area under the drainboard is sealed and has a drain line connected to the sink drain. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087664419-D08IS0MDD2DS5D210WMC/GreenGateIMG_6041.jpg Manayunk Kitchen The breakfast bar in the dining room has custom-built bamboo corbels. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479087665793-JZFIXYLKBSDCSDK3GZRC/GreenGateIMG_60361026.jpg Manayunk Kitchen Looking into the kitchen from the dining room. We recessed the fridge into the wall a bit to pick up extra floor space in the kitchen. http://www.greengatewoodworks.com/spring-house-1 daily 0.75 2018-02-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085591624-D6MDH9LSFRSR9PJ9OT3Q/IMG_0074.JPG Spring House A long-time client called up and asked me to come up with a solution to drain her constantly wet yard. After a little investigation I found a spring bubbling up underground. I came up with an idea to use this unique opportunity to create a stream and small pond instead of just installing a standard drain pipe and burying everything underground. In this picture the upper part of the stream has begun to take shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085596283-SQHBXR7B4UX9EO65UYFG/IMG_0082_1.JPG Spring House Installation of the liner https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085598892-1ZQ9PI2CPJOG78OH01L9/IMG_0094_1.JPG Spring House We brought in several tons of river rock to create the stream bed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085601555-XJ00W78Z6SCLP7Y5YS4J/IMG_0101.JPG Spring House Installation of the plants. We also installed several pieces of flagstone at the dam sites along the stream to create small waterfalls. These waterfalls in turn created a relaxing, babbling sound. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085604617-R4FUOUT61O09OZ9PIYUW/IMG_0110_1.JPG Spring House All the plants are in, and the beds are mulched. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085604100-5DZRR6ETP37ODSCFWVLY/IMG_0114.JPG Spring House After the mulch was installed, I began to create a small spring house that would give the stream a more definitive starting point. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085608877-SIG5YHZ47IPLFJQ0LC5P/IMG_0123.JPG Spring House After installing the roof rafters, I put on a cedar shake roof. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085610719-U92K5GJT5MPYQ8G6V6ZR/IMG_0149_2.JPG Spring House Trim and siding installed, along with a copper ridge cap https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479085613558-11J34LJYM2BG48J2X2R0/IMG_0151_2.JPG Spring House The finished product. This was an interesting project and a little outside my normal routine but still a fun design process. Thanks to Brendan Gibbons and his guys for providing a lot of extra hands to get things done. If you're looking for a good landscaper, go to http://www.brendangibbonsco.com to get in contact with him. http://www.greengatewoodworks.com/new-page daily 0.75 2018-02-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477783036594-2W4W8RFYAA3EY2833NI6/Cohn+bathroom+renovation+-+cabinet+construction+5.JPG Cherry Vanity As part of a larger bathroom renovation, I was commissioned to make a custom cherry vanity. Here the base cabinets have been assembled and had the face frames attached. All the cherry face frame and drawer parts were milled down from rough lumber in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477783036886-XVPN1H53YG28CNIBEYQB/Cohn+bathroom+renovation+-+cabinet+construction+6.JPG Cherry Vanity The end panel on each drawer base is a cherry veneer, left unstained to provide contrast to the rest of the piece. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477783038845-CHS0RJNZQQ52ZNZV1FIN/Cohn+bathroom+renovation+-+cabinet+construction+19.JPG Cherry Vanity Installed in the client's home. The cabinet doors were built with the same cherry veneer to match the end panels. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1477783039232-6E7HDB34SJOR2F7MYMXI/Cohn+bathroom+renovation+-+finished+cabinet+6.JPG Cherry Vanity Hardware installed, along with the top and sink. The piece was finished with several coats of polyurethane which helped to mellow the contrast between the stained face frame and the unstained veneer panels. http://www.greengatewoodworks.com/butlers-pantry daily 0.75 2018-02-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084777099-SHA941RBRRVKNC40550E/IMG_2391.JPG Butler's Pantry For this project, the client gave me two antique windows to repair and turn into doors for a built-in butler's pantry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084805579-L2O31QTBEMG225T1NDU4/IMG_2561-2.jpg Butler's Pantry The finished cabinet installed in the client's home. She opted to do the finish painting herself, so these pictures only show the primed unit. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084808591-YPDKXRZGOJDJLMS0GSBJ/IMG_2579-1.jpg Butler's Pantry In keeping with the older character of the windows, I used a sawtooth shelf system instead of the shelf pins used in more modern furniture for both the upper and lower cabinets. Each shelf sits on a small board that fits into the teeth of the side rails. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1479084809446-96IDJ9H0833SZ7H4KJMN/IMG_2581-1.jpg Butler's Pantry Close up of the storage area between the two cases. I made the countertop out of maple and stained it to match an existing one in the home. http://www.greengatewoodworks.com/cherry-mantle-fireplace-surround daily 0.75 2018-02-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1496881628571-3LMUCV2Y1ES00VVJ1O8L/IMG_2592.JPG Cherry Mantle & Fireplace Surround A long-time client of mine hired me to do a number of different jobs while they were out of town. One of the projects they gave me was to renovate their fireplace and give it more of a rustic feel. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276105-DUFDGFVVF9FQWTAJ7EJV/IMG_0011-B.jpg Cherry Mantle & Fireplace Surround A shot of the completed project. We installed new cables and a mount for the TV, new fireplace doors, veneer stone to match the exterior of the home, and a custom made cherry mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276471-979MUPQGEDJAYRCD62H5/IMG_0083.jpg Cherry Mantle & Fireplace Surround Closer shot of the mantle and TV https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276468-UZFZ3A3UUTXHO42DDMCO/IMG_0087.jpg Cherry Mantle & Fireplace Surround A closer shot of the mantle https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276853-IQ591NBA5NQTMX10NQCR/IMG_0092.jpg Cherry Mantle & Fireplace Surround The mantle and corbels were fabricated from a single cherry slab. The original slab had a split in it which I included in the mantle by filling it with a structural epoxy that dries clear. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1478973276851-HBOYE7XEHE0CFCIX5XY2/IMG_0096.jpg Cherry Mantle & Fireplace Surround Beautiful grain patterns on the custom made corbels http://www.greengatewoodworks.com/secret-door-1 daily 0.75 2018-02-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1491616789542-TC8ZLOVKTR42AYNJMI0I/CIMG0080.jpg Secret Door As part of a basement renovation I got to make this really cool secret door inside a cedar closet. I designed the entire system from scratch and built it using standard materials from the hardware store and some parts I had laying around my shop.   There are two videos next in the gallery; the first one shows a quick look inside the closet showing how it appears to be a standard cedar closet, and the second shows the secret door in operation. I took the videos with my phone at the time, so they're not the highest quality videos, but they're all I have of this particular project. http://www.greengatewoodworks.com/mid-century-stereo-console daily 0.75 2018-07-31 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080201707-PFP8QUA6SG130Q2SNUEI/IMG_8077.jpg Mid Century Stereo Console This mid-century style stereo console was commissioned by a client in Boston to house his turntable and other stereo components. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080201808-OLILQRAGLSSX77Q8VHLM/IMG_8078.jpg Mid Century Stereo Console Painted in Sun-Kissed Yellow, this piece really catches your eye. I chose oil-rubbed bronze hardware to pop against the vibrant yellow. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080202872-XPBIID234NH1B7S69125/IMG_8079.jpg Mid Century Stereo Console The doors open up for easy access to the stereo components. Hidden underneath the shelf is a power strip to neatly contain all the necessary plugs, and only a single cord comes out of the back of the console. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080202895-1DAW6TN34V8L06QL7NZD/IMG_8080.jpg Mid Century Stereo Console The top of the console opens fully as well to allow access to a turntable on the top shelf. Three holes allow for power or other cable to pass from the upper area to the lower. An additional hole in the rear of the console allows for wiring to be run out for speakers. http://www.greengatewoodworks.com/xl-farmhouse-table-1 daily 0.75 2018-08-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080946441-TRULBLXKVQQDHKFL9JWD/IMG_3959.JPG XL Farmhouse Table This farmhouse table was commissioned by a client looking for a large sturdy table to use for family gatherings. I designed a traditional trestle table with large sturdy legs to match the 2-1/2” thick maple top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080936437-U0XD7E5WFB8Q5UCYZR1J/IMG_3952.JPG XL Farmhouse Table The top opens up to expand the table for larger groups. The two main sections of the table top were heavy enough that traditional table slides weren’t strong enough to handle them. I designed this all-steel mechanism along with Joe Messner from JGM, Inc to handle the excessive weight. When fully extended to allow for removal of the two table leafs below, there is virtually no deflection across the top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080936412-CHW8BJR4ZVSP5VVAI3QH/IMG_3953.JPG XL Farmhouse Table With both leafs in place, the table is 48” wide by 120” long and can seat eight to ten people. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080946860-8GBPC6Z1BAE40MN1SM1J/IMG_3958.JPG XL Farmhouse Table When not in use, the table leafs store below the top on a shelf that stretches between the table legs. I designed the tops and leafs to fit together with an offset edge because I found it both challenging and visually interesting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080956058-LEJQOB7R84V3N6YDARB7/IMG_3960.JPG XL Farmhouse Table The large stretcher that runs between the bottom sections of the table legs adds additional rigidity to the overall piece. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080956303-V71GPNUOL3GT1LSNGQIA/IMG_3962.JPG XL Farmhouse Table The visually (and actually) heavy legs were lightened by the introduction of the diamond-shaped cutouts, and the overall design of the legs was based on a classic ogee profile. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533080965985-5BXPF1FDIQ64UDYNCVU5/IMG_3963.JPG XL Farmhouse Table When the leafs are stored away, the table is 78” long and can seat 4-6 people comfortably. http://www.greengatewoodworks.com/berwyn-kitchen-renovation daily 0.75 2018-08-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533089548123-6R2ZKIAUAMAHOIZ3J8NL/Davis+kitchen+before+1.jpg Berwyn Kitchen Renovation A client contacted me to totally renovate their kitchen and mudroom. This is a before shot looking from the kitchen doorway towards the mudroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533089539582-MUVAK3O9B9YQOW15EGL1/Davis+kitchen+before+2.jpg Berwyn Kitchen Renovation The other side of the original kitchen, with the doorway to the dining room on the right. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533089565844-6HQ03JO1XFWO1GDFXO98/Dining+room+Davis+before.jpg Berwyn Kitchen Renovation This is the dining room adjacent to the kitchen. Part of the renovation plan involved removing the wall between the two rooms, and replacing the dining room window with an atrium door.. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083187033-LNXKW4SW51OJYB19G0KI/IMG_3887-86.jpg Berwyn Kitchen Renovation The finished kitchen, as seen from the dining room with the wall removed. After installing the structural beam, I wrapped it in white oak to give it an antique look. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083187330-2MY1NXWIC96HRAF33LAN/IMG_3897.JPG Berwyn Kitchen Renovation Looking into the new kitchen towards the mudroom. I removed the linoleum floors and refinished the original subfloors to match the other existing floors in the house. Other work included new appliances, new cabinetry, recessed lighting, and new trim pieces to match the home’s original trim scheme. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083202428-OP9YKJGYNK365WS35PH4/IMG_3902.JPG Berwyn Kitchen Renovation Looking into the kitchen from the mudroom doorway. I reframed the original basement stairwell wall and extended it slightly to allow for more wall space for the new oven and vent hood. The clients opted to handle the painting themselves and also installed the tile backsplash. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083224202-LTDMUKZCN92F9OP4FHDZ/IMG_3916.JPG Berwyn Kitchen Renovation I installed a new glass door for the basement stairwell that let more natural light into the kitchen from an existing exterior door in the stairwell. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083201665-E2894TJDIPKPAQMXUUOM/IMG_3906.JPG Berwyn Kitchen Renovation In the original mudroom there had been a small water closet. Part of the renovation included expanding it into a proper powder room. This powder room got new fixtures, cabinetry, lighting, flooring, and a slimline radiator. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083214143-I1PPZTVBQNF224ZLVMJO/IMG_3909.JPG Berwyn Kitchen Renovation The remainder of the mudroom received a new lowboy radiator, rough-sawn floating maple shelves, refinished floors, and a new mudroom bench with a solid maple top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083215475-VZ3IGO2CR3KJ3971ZGRI/IMG_3914-13-flat.jpg Berwyn Kitchen Renovation The new atrium door that replaced the original dining room window allows more natural light into the room as well as access to the backyard. . https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1533083225195-BX9W42PZS0E0C8QSOMYA/IMG_3921.JPG Berwyn Kitchen Renovation One last shot looking into the kitchen from the front room of the house. http://www.greengatewoodworks.com/curved-drawer-1 daily 0.75 2018-08-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466774805-8TINR9IT4COJSPTCX1LH/IMG_9034.JPG Curved Drawer These are the templates I made - one for the face frame and drawer front, and the other for the front wall of the drawer box. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466777297-V2RMIE4PKS18VOYVNZJ9/IMG_9035.JPG Curved Drawer The face frame/drawer front template was based on the curve I cut into the cabinet case, and then the drawer box template was based off of that so they mated nicely. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466712661-EAOTLOCM5CVTUQJ72A5N/IMG_8476.JPG Curved Drawer Using the templates, I cut out pieces from 1x material and stacked them up as needed to get the necessary height. These two pieces are the top rail of the face frame. If you zoom in, you can see the pencil line from the template. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466712630-6HTR03UDS2U7TK5R8AH3/IMG_8477.JPG Curved Drawer Using the stand sander belt, I trimmed the pieces flush to the pencil line. To get the inner curve, I took the top cover off the sander belt to uncover the top spindle, and then used that to get close to the line. The inner curve is the outer face of the pieces, so I left those a little heavy and chased them down with a orbital sander later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466716701-0M15IS9CFYZFVBO2S0FQ/IMG_8495.JPG Curved Drawer The piece in the back is for the front wall of the drawer box, and the front piece is one of the rails from the drawer front (I think). Either way, it shows you how they look stacked up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466720157-HWQXTWB4RERWP9886OXJ/IMG_8512.JPG Curved Drawer For the stiles on the drawer front, I used 5/4 stock and held it up to the curved rail that I had trimmed to the correct approximate length. Then I put the template over top to get the curve marked. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466719983-M8HHP1NG18TAMZNP17KQ/IMG_8513.JPG Curved Drawer Some more work on the belt sander to get it close to the pencil lines. Again, I left them heavy to chase down later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466724235-25JK6VS3WZRX4QS4XXW3/IMG_8515.JPG Curved Drawer I joined the rails and stiles together with my domino jointer, using 8mmx40mm dominoes I think. I couldn't go too long with the dominoes for fear of them popping out of the face when I was cutting them in. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534467687644-PCXAGL8V7TMZ3US26QUN/IMG_9045.JPG Curved Drawer Bit of jump right now: for the drawer boxes, I was making them out of solid maple with a housed rabbet joint pinned with walnut dowels. For the curved drawer, I made up the drawers box with 3 parts (back and two sides) and a temporary short front piece so I could clamp it up and get it to the right dimensions. Then I held the curved piece over top of it and marked the joint with a pencil (visible in the next photo). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466729843-S141UVJU363FO711GA7Q/IMG_8588.JPG Curved Drawer In order to cut the joint out for the drawer box front wall, I made up 2 different jigs, this being the first of them. This one (made from scrap I had laying around), allowed me make the first couple cuts. Biggest issue with this was eyeing up the blade angle and sneaking up on the pencil lines. I’m not sure if it’s visible in this picture or not, but I marked the center line of the drawer piece so I could flip it over and get the same approximate cut on the other side. It still took some adjusting, but it got me in the right ballpark. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466733405-OPTRWSM6UXGSBO1F3FYB/IMG_8589.JPG Curved Drawer Closer shot of what I was cutting out on the first jig. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466740945-EMZC7IG567HMT50EIJLC/IMG_8593.JPG Curved Drawer This is the second jig to complete the cuts. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466740890-FL3EZLP7L43OF0X2D30H/IMG_8594.JPG Curved Drawer Close up of the piece on jig #2 before cutting it. I also added some side walls after I took this picture so I could run it through the table saw without the base coming apart. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466744078-YOP1C14O14I41F7LC78L/IMG_8595.JPG Curved Drawer After the cuts were made. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466746603-RU8XAW0HYHN6NZOOSWU8/IMG_8597.JPG Curved Drawer Top view of the finished joint. I ended up over cutting it just a stitch. Next time around I’d leave the pencil lines and chase them out by hand with a chisel. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466747800-DSR4WN56T4WGUWHXOTCK/IMG_8598.JPG Curved Drawer After the side joints were cut, I ran it through the table saw to cut in a kerf for the drawer bottom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466758081-GX4OEIB5B06OBGBLHWRE/IMG_8604.JPG Curved Drawer The drawer box dry fit https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466760980-7CCKJJSW6WZ2E69N1N5P/IMG_8605.JPG Curved Drawer Glued up and clamped. The front wall bowed in a bit with the pressure from the clamps, so I used a spreader in the middle to push it back into the correct place (using the template to get it right). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534468464280-I1JHM715VHO6NW8IR36Z/IMG_8518.JPG Curved Drawer This is the drawer front being clamped up. I used a laminate trimmer/router to cut in grooves for the center panel to sit in. The center panel was made from 1/4” plywood that I kerfed on the backside to make it easier to bend. Clamping it up was a pain in the ass. To do it again, I’d make up another jig for it to sit over top of, with the outer face facing down so I could clamp it down into position. This way worked, but it ended up skewed a bit diagonally. I was able to pull it back into position when I attached it to the drawer box, but it was just an unnecessary difficulty I’d try and avoid next time around. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466768257-WVDNEGA98SDF0YYRO8FM/IMG_9002.JPG Curved Drawer After attaching the drawer front to the drawer box, I put in the slide hardware. I use Blum Movento slides with the depth adjusters (about $50 a pair from Lee Valley. They’re pricier than others, but they have a lot of adjustments to them which makes installation a lot easier). I had bought 20” slides - they were the right length for the other square drawers, but with the curve they ended up being too long because the front hardware (orange parts in the pic) had to be back further to operate properly. Instead of ordering shorter slides and delaying everything, I just put some spacer blocks on the back of the drawer to make it work (they’re never seen unless the drawer is taken out). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466781949-XR7GKL21TYK84TVPHUYL/IMG_9038.JPG Curved Drawer This is a close up of the drawer face top rail. You can see the joints in it and the grain change, but I’m painting it so it won’t matter. If I was doing stain grade work, I’d try and find quarter sawn material all from the same board if possible to minimize grain change and color differences. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534469079625-UAZINRHGLNE0WRE3ZH0D/IMG_9039.JPG Curved Drawer This is the inside of the drawer box where you can see all the layers stacked up. This isn’t getting painted, but since it’s the inside front of the drawer I wasn't too concerned about it being seen. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466791447-0B03APOK2ABHIHRN6YG6/IMG_9042.JPG Curved Drawer Top view of the rabbet joint. I had to fit in some little shims to close up a couple gaps. This was the result of taking too much off on the table saw, and if I’d snuck up on it with a chisel I probably could’ve gotten a better looking joint. One thing to note, the front wall of the drawer box is about 3/4” thick, whereas the sides are 9/16” thick. The sides have to be 5/8” thick or less for the drawer slides I was using, and I had initially thought I’d just sand the front wall down to 9/16” as well. However, when I marked the joint, I realized I couldn't go any thinner than 3/4” or the joint wouldn't work right. It’s annoying that they’re different, but this could probably be avoided by using a different joint entirely. Dovetails would probably work okay with two pieces the same thickness, but I’d have to experiment with it to be sure. I started using this pinned rabbet joint a while back because it’s a lot faster to make in the shop and people like the walnut/maple contrast so I just instinctively used it again on this project, not realizing it was going to cause this issue later on. Again, not a big deal, just sort of annoying although I’d be shocked if anyone ever noticed it besides me. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1534466800830-JL2M6WJ6RE7WEHX3XADM/IMG_9049.JPG Curved Drawer Normally I pack out the inner side walls of my cases to line up exactly with my face frames and then attach the slides to the pack outs. In this case, the side walls of the case are not at the correct angle to make that work, so I glued up some 1x stock and made this little side supports. The vertical bit in the back provides extra pressure to keep the back of the side supports from lifting up when the drawer is fully extended. The side supports are glued and tacked down, but I didn’t want to rely on just that. One pain with this method was making sure the slides were parallel the whole time so they’d operate properly. Since this is a center unit flanked by other parts of the banquette, I could cut access holes in the side of the case to allow me to see inside and mark things with a pencil while moving the drawer in and out. I don’t think that’ll work for your project since I imagine the piece you’re making will be a stand-alone one, but you might want to consider mounting any hardware like this before you put the sides together. That way you could see everything you need to see and have it all set before putting the rest of the case together. http://www.greengatewoodworks.com/outdoor-fireplace-mantle-1 daily 0.75 2018-09-19 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317864500-94U3JEGJNOLWMJ7FWVMN/IMG_8231.JPG Outdoor Fireplace Mantle A landscape design firm I work with on various projects came to me with a client who wanted a mantle for their new outdoor fireplace. We decided upon one of the 200-year-old red oak barn beams I have in stock. After doing some layout to preserve the original joinery that was still intact, the next step was cutting it to length. To maintain the proper look, I used a traditional handsaw in lieu of more modern power saws. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317864186-HA1S80GHA6K8DIT59723/IMG_8233.JPG Outdoor Fireplace Mantle The freshly cut end was glaringly bright in contrast to the two centuries worth of patina on the rest of the piece, so I used a torch and a few other methods to antique it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317869722-Y9IKFLTN05L86VE8PP5Z/IMG_8235.JPG Outdoor Fireplace Mantle The freshly antiqued cut end of the beam. After the finish is applied, the end blends in seamlessly with the rest of the beam. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317870294-K5R66PEU8Q7RZQZ6DAQI/IMG_8237.JPG Outdoor Fireplace Mantle A wider shot of the trimmed beam before finishing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317828191-16H33CZEU41L01NLZEQ1/IMG_9109.JPG Outdoor Fireplace Mantle The finished beam installed on the new outdoor fireplace. The two pockets on the front face are original mortises that include the original draw bore pegs that were used to hold the tenon of a mating piece snugly in place. A portion of one of those tenons is still visible within the left side mortise. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317826404-GFMWRCTMG8D269YDM3MN/IMG_9107.JPG Outdoor Fireplace Mantle Looking down the left side of the mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317828121-Q9N32VKXH9Y02MUMRDYU/IMG_9108.JPG Outdoor Fireplace Mantle Looking down the right side of the mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537317826277-LGU0ED95VOMER8621IQO/IMG_9106.JPG Outdoor Fireplace Mantle A wider shot of the outdoor fireplace and mantle. The fireplace, patio, retaining walls, and all stonework were built by Doyle & McDonnell, Inc of Berwyn, PA. http://www.greengatewoodworks.com/butcher-block-countertop-insert-1 daily 0.75 2018-09-18 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281672859-86OA5WTKC0HVW4OQW2NV/IMG_9142.JPG Butcher Block Countertop Insert A client commissioned me to make a butcher block insert to fill a hole where a cooktop was going to be removed from their kitchen counter. I started by milling down maple into square boards and then gluing them up into these two blanks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281681086-SCDKGHXSZ5HK325RQNDI/IMG_9169.JPG Butcher Block Countertop Insert After the glue was set, I ran the blanks through a wide belt sander to clean them up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281685377-SSPLXQ5K7YHWYWZPFWDF/IMG_9173.JPG Butcher Block Countertop Insert Next, the blanks were cut across their width into 3” tall strips. The strips were then glued up to make the end-grain butcher block blank. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281619506-08S0PX1UHH63I0JBIN96/IMG_9218.JPG Butcher Block Countertop Insert The blank was then trimmed and shaped to allow the lower 1” of the butcher block to recess into the countertop. The edges were also rounded over and handles were cut in at either end. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281663327-EQM84Y33IZCAM2OIET7H/IMG_9191.JPG Butcher Block Countertop Insert The butcher block was finished with multiple coats of mineral oil. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281676750-T9WV0QQI5IV0OAPMAOOA/IMG_9193.JPG Butcher Block Countertop Insert The oil gives the butcher block a nice warm color and helps to seal it against water, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1536281689288-6IWZFLCUXKJ5D4WMEH64/IMG_9236.JPG Butcher Block Countertop Insert Installed in the client’s home. A few extra maple blocks are used underneath to hold the butcher block securely in place, while allowing for easy removal for cleaning. http://www.greengatewoodworks.com/curved-banquette-1 daily 0.75 2018-09-19 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387197367-G3CN9MWM8L6QSEYGR1Y6/IMG_8225.JPG Curved Banquette A client contacted me for a built in banquette project, and during our meeting I came up with an idea for a curved seat. The case pictured here is the center unit with the curve for the seatback marked out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387197047-07HEBAXB9Y6BNAEYKYM2/IMG_8952.JPG Curved Banquette Two additional cases flank the center one, each case with a single drawer. The struts on along the rear wall provide support to the curved back piece. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387208475-X7NHSLWN3M1GNC3OR7YM/IMG_9131.JPG Curved Banquette The bases ganged together for installation. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387214709-UUUU46S7WY0RX72FE3WR/IMG_9244.JPG Curved Banquette After the cases were secured, I bent several layers of thin plywood and secured them to the support struts shown earlier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387223162-TF8DIGW8PCTT9HQTD8J5/IMG_9257.JPG Curved Banquette With a project like this, a lot of custom templates and jigs are required to manufacture the necessary parts. This template was for the plywood seat base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387228327-U8CWT2K4K5KSMC6YM26U/IMG_9267.JPG Curved Banquette The plywood seat fit and installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387734936-GGBHSYM2VXL4TBLBRTJ3/IMG_8604.JPG Curved Banquette Each of the three units got a solid maple drawer box using housed rabbet joints pinned with walnut dowels (not visible here). This drawer box for the center unit was one of the more challenging aspects of this project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387234216-FGONNUNAZNR1E4MQA7U0/IMG_9274.JPG Curved Banquette After fitting the drawers in the cases, I installed an upper plywood cap to tie everything together and trimmed out the back wall to create a paneled look. I also bent and installed trim and baseboard pieces to tie the project into the existing trim scheme. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1537387237971-TE1O3A56VKT5L0Y6E9Q5/IMG_9299.JPG Curved Banquette The finished painted banquette with handles installed on the drawers. http://www.greengatewoodworks.com/st-davids-built-ins-1 daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311689407-FNFCOT3XB2E2NVIFXLTR/IMG_0028.JPG St. David's Built Ins I was commissioned for a set of built-ins by a client. After building and priming the cases in my shop, I started installation. Here the lower cases have been set. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311693439-WXP8P7JX4T4U3A9IM19A/IMG_0034.JPG St. David's Built Ins After installing the lower column sections, I was able to make up a template for the countertop. I took that template and used it to size the maple countertop blank I had built in the shop. After sanding, staining, and finishing it, it slid into place perfectly on site. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311701106-KFM3MCWXZ98J3VZXVEKF/IMG_0037.JPG St. David's Built Ins After the countertop was installed, I could begin installation of the upper units. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311721658-N1JCR2P3IX2C9X0F8KJK/IMG_0076.JPG St. David's Built Ins Here the upper column portions have been fit and installed, and the crown and baseboard trims are complete. A mount for the television has also been installed along with a chase to bring data cables up to the TV from the lower center cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311730248-QHS1LK3OCYMUYAXUAN5W/IMG_0080.JPG St. David's Built Ins Hanging the doors and the TV. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544311736222-HG5M1CI0EYOD0DYWRFA2/IMG_0110.JPG St. David's Built Ins The finished product features sawtooth adjustable shelves, beaded face frames, solid maple raised panel inset doors, and hand-made wrought-iron handles. http://www.greengatewoodworks.com/new-page-3 daily 0.75 2018-12-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045559839-7P0BOO65FAEBB0GLFAIT/IMG_0032.JPG New Page Sometimes I have to make up little jigs or tools to help me around the shop. I was working on a built in project the had a fairly large maple countertop, and it was a bit too heavy to move around myself safely. So I designed and built a pair of dollies to help carry it. The design allows them to automatically clamp down on the countertop as it’s lowered between the upper jaws. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045567361-4LDIBZBS057VOTIFW5F6/IMG_0046.JPG New Page The 13’ long maple countertop loaded up in the dollies. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045566749-Z74R441NRVNSB1OWL706/IMG_0048.JPG New Page Even with the snow on the ground, these little dollies made it a breeze to load up the countertop. Certainly not the prettiest things I’ve ever built, but extremely helpful in a situation like this. http://www.greengatewoodworks.com/fireplace-surround-1 daily 0.75 2018-12-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544005143833-7JYH0XTOIIILSQ27YCDT/IMG_0174.jpg Fireplace Surround A client contacted me about creating a surround for their fireplace. After discussing some options, I came up with a design and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544005108592-5OIFRP6WT66ZLCSMT4GK/IMG_0175.jpg Fireplace Surround The finished product has a flat panel design for the lower half, and custom horizontal wainscot paneling on the upper half to echo the existing horizontal paneling on either side of the fireplace. Custom corbels support the new mantle, and the top is finished with a large double crown. http://www.greengatewoodworks.com/new-page-4 daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304679082-SBEGOXXH4T8CM0ANUWU9/IMG_9552.JPG Chalkboard Cabinet Doors A client contacted me about installing some pull out shelving and cabinet doors with blackboard panels in this cabinet where their refrigerator had been previously. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304679244-4NDL5C81WL9M5NBXSHKQ/IMG_9554.JPG Chalkboard Cabinet Doors First step was to install a floor and toe kick to match the other cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304683227-VY7X1KQFPOQ6INAC55M7/IMG_9565.JPG Chalkboard Cabinet Doors Next up was installing framework to support the shelves, and then hang the shelves themselves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304683471-400ZGP5MLO5P9IQRENJG/IMG_9566.JPG Chalkboard Cabinet Doors Each shelf pulls out fully and is made from solid maple and uses a housed rabbet joint at each corner with a walnut dowel detail. The dowels help to reinforce the joint while also giving it some visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304632097-4EAEQNN8I9CQAFWWSP5S/IMG_9588.JPG Chalkboard Cabinet Doors After the drawers were installed, I hung and fit the doors that I had made in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304632184-Y8IUDR3GVIX3761XLSBB/IMG_9589.JPG Chalkboard Cabinet Doors A shot of the cabinet fully opened and drawers extended. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304695165-CRYV33IL5LLP9KDJ3S9X/IMG_9590.JPG Chalkboard Cabinet Doors The doors are made of solid red oak to match the other cabinets in the kitchen The center panels are painted with chalkboard paint on both sides and provide plenty of space for notes, grocery lists, etc. http://www.greengatewoodworks.com/new-page-2 daily 0.75 2018-12-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544006103685-1W0DVTUZJPAIFYVRBSRH/IMG_0176.jpg Cedar Fence, Part 2 A few years ago, I had built and installed a custom cedar fence for a client (visible on the left side of the photo. To see the full project, click here). They contacted me later to extend the fence along the other side of their property. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544006106599-2J8G4BAPRZ0TP22KJNLC/IMG_0177.jpg Cedar Fence, Part 2 The completed matching fence, made from knotty western red cedar planks, and finished in an oil-based sealer. Offset planks allow for privacy while keeping the overall fence visually light. http://www.greengatewoodworks.com/chalkboard-cabinet-doors-1 daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304679082-SBEGOXXH4T8CM0ANUWU9/IMG_9552.JPG Chalkboard Cabinet Doors A client contacted me about installing some pull out shelving and cabinet doors with blackboard panels in this cabinet where their refrigerator had been previously. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304679244-4NDL5C81WL9M5NBXSHKQ/IMG_9554.JPG Chalkboard Cabinet Doors First step was to install a floor and toe kick to match the other cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304683227-VY7X1KQFPOQ6INAC55M7/IMG_9565.JPG Chalkboard Cabinet Doors Next up was installing framework to support the shelves, and then hang the shelves themselves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304683471-400ZGP5MLO5P9IQRENJG/IMG_9566.JPG Chalkboard Cabinet Doors Each shelf pulls out fully and is made from solid maple and uses a housed rabbet joint at each corner with a walnut dowel detail. The dowels help to reinforce the joint while also giving it some visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304632097-4EAEQNN8I9CQAFWWSP5S/IMG_9588.JPG Chalkboard Cabinet Doors After the drawers were installed, I hung and fit the doors that I had made in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304632184-Y8IUDR3GVIX3761XLSBB/IMG_9589.JPG Chalkboard Cabinet Doors A shot of the cabinet fully opened and drawers extended. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304695165-CRYV33IL5LLP9KDJ3S9X/IMG_9590.JPG Chalkboard Cabinet Doors The doors are made of solid red oak to match the other cabinets in the kitchen The center panels are painted with chalkboard paint on both sides and provide plenty of space for notes, grocery lists, etc. http://www.greengatewoodworks.com/new-page-5 daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304679082-SBEGOXXH4T8CM0ANUWU9/IMG_9552.JPG New Page A client contacted me about installing some pull out shelving and cabinet doors with blackboard panels in this cabinet where their refrigerator had been previously. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304679244-4NDL5C81WL9M5NBXSHKQ/IMG_9554.JPG New Page First step was to install a floor and toe kick to match the other cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304683227-VY7X1KQFPOQ6INAC55M7/IMG_9565.JPG New Page Next up was installing framework to support the shelves, and then hang the shelves themselves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304683471-400ZGP5MLO5P9IQRENJG/IMG_9566.JPG New Page Each shelf pulls out fully and is made from solid maple and uses a housed rabbet joint at each corner with a walnut dowel detail. The dowels help to reinforce the joint while also giving it some visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304632097-4EAEQNN8I9CQAFWWSP5S/IMG_9588.JPG New Page After the drawers were installed, I hung and fit the doors that I had made in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304632184-Y8IUDR3GVIX3761XLSBB/IMG_9589.JPG New Page A shot of the cabinet fully opened and drawers extended. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544304695165-CRYV33IL5LLP9KDJ3S9X/IMG_9590.JPG New Page The doors are made of solid red oak to match the other cabinets in the kitchen The center panels are painted with chalkboard paint on both sides and provide plenty of space for notes, grocery lists, etc. http://www.greengatewoodworks.com/clamping-shop-dollies daily 0.75 2018-12-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045559839-7P0BOO65FAEBB0GLFAIT/IMG_0032.JPG Clamping Shop Dollies Sometimes I have to make up little jigs or tools to help me around the shop. I was working on a built in project the had a fairly large maple countertop, and it was a bit too heavy to move around myself safely. So I designed and built a pair of dollies to help carry it. The design allows them to automatically clamp down on the countertop as it’s lowered between the upper jaws. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045567361-4LDIBZBS057VOTIFW5F6/IMG_0046.JPG Clamping Shop Dollies The 13’ long maple countertop loaded up in the dollies. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544045566749-Z74R441NRVNSB1OWL706/IMG_0048.JPG Clamping Shop Dollies Even with the snow on the ground, these little dollies made it a breeze to load up the countertop. Certainly not the prettiest things I’ve ever built, but extremely helpful in a situation like this. http://www.greengatewoodworks.com/green-gate-sign-2-1 daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307184510-5TH22E8JXI383JV7C8VI/IMG_9221.JPG Green Gate Sign #2 The first sign I made for outside my shop ended up getting damaged in a storm, so I decided to make another. I went with a smaller, more ornate overall design this time, and decided to go with a solid white oak sign for this one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307189928-5FM8ZDL7Y3C5B3RVGGI9/IMG_9223.jpg Green Gate Sign #2 After designing a revised logo in Photoshop, I printed it to scale and taped it on top of the white oak blank. Then I used a marking knife to trace all the lettering. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307193796-WT3TDHXZRF3P469VV0II/IMG_9231.jpg Green Gate Sign #2 After all the tracing was done, I removed the remainder of the logo printout. Then I used a trim router to carve out the letter areas so they were slightly recessed from the main face of the sign. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307221952-8W5I6IQNVTEDOL8NONL1/IMG_9372.JPG Green Gate Sign #2 After finishing with the router work, I painted the entire sign white, and then painted the raised areas a dark green. This photo was taken midway through the painting when it was still a bit patchy, and it didn’t have the outer edge color on yet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544307241716-VJTLBKO3SDDBD9RKBHMQ/IMG_9533.jpg Green Gate Sign #2 For the sign post itself, I used a cedar 4x4 for the upright, and then carved out a mortise to slide the 2x4 cedar arm through. After that, I pinned the joint with two red oak dowels and rounded over the cut edges. The arm is also secured using the decorative wrought iron bar on top. The cedar post was treated with a preservative for the portion that was underground, and above ground it was sealed with a spar urethane. It was set into a small garden of ornamental grasses to protect it from the lawnmower. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544309906070-1G3F0FWM7VIY5S9P3NCD/IMG_0232.jpg Green Gate Sign #2 A finished picture of the sign out at the front of our property. http://www.greengatewoodworks.com/spalted-maple-mantle-1 daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305715458-D4GONO56RXD275NQFJP0/IMG_0196.jpg Spalted Maple Mantle This spalted maple slab, along with a couple of other pieces, was picked by a customer to use for a few projects she had in mind. This slab in particular was chosen to become a mantle in her home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305715709-BYRC41B4QKEU1JN2M06N/IMG_0197.jpg Spalted Maple Mantle After looking over the slab for a while, I decided upon where to make my cuts. I use the tape to layout how the main section of the mantle will look so I can get a good idea of how the grain, etc will look in the finished product. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305716481-HHPBL0OT5SP11B7I8TN2/IMG_0198.jpg Spalted Maple Mantle After trimming off the excess from the original slab, this was the piece left over for the mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305717165-K72MGTMXBZVS3NWAB7NR/IMG_0199.jpg Spalted Maple Mantle The cutoffs from the original slab were used to create a pair of these simple corbels. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305717651-OLFRYUDIXTO7RYD42LKI/IMG_0200.jpg Spalted Maple Mantle After multiple passes with a thin epoxy to fill the many wormholes in the wood, I was able to apply a varnish coat which really brings the colors in the piece to life. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305718065-D1XC4DBTACGQ0ZOV1ZPD/IMG_0201.jpg Spalted Maple Mantle The finished mantle installed in the client’s home, just in time for Christmas as per her original request. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1544305718572-G94A5BN0S7IQ85738TMZ/IMG_0202.jpg Spalted Maple Mantle A closer shot of the finished mantle. I was really happy with the way this project turned out. It fit the room perfectly and the colors in the wood were absolutely fantastic. http://www.greengatewoodworks.com/minimudroom-1 daily 0.75 2019-02-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549031943803-MSX8QYFMN3YQRL7FNHU8/IMG_0243.jpg Mini-Mudroom A longtime client asked me to create a mudroom space for them in this little corner by their front door. They liked the look of a mudroom locker built in I had done a few years back with black walnut benches and white trim work, so using that as inspiration we moved forward. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032542706-K6ORAWDWZRGRQ1XTQPK1/IMG_0366.jpg Mini-Mudroom This is the finished built in. The space was too small for traditional lockers, so multi-tiered swiveling hooks were installed to maximize storage, and the area under the bench was also left as open as possible for the same reason. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032622528-6AA6W28VR6UV1L7FXX6C/IMG_0367.jpg Mini-Mudroom The back wall of the built ins has a flat panel look to mimic other trim work in the home, and the black walnut upper shelf creates additional storage for smaller items. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032624668-9X0MDBJDQH45N5U99RNE/IMG_0368.jpg Mini-Mudroom The client didn’t want a live-edge on the benches, but I was able to incorporate the lighter sapwood of the black walnut to create some visual interest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032626525-M6S8GM6GCBCFURZMJ5A5/IMG_0369.jpg Mini-Mudroom The miter joint where the two sections come together was carefully cut so that the lighter sapwood would transition cleanly around the inside corner. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549032628833-6360FGIGOZXMEF6SACB7/IMG_0370.jpg Mini-Mudroom A closer shot of the tiered hooks. Each one has 4 hooks on 3 swivels that accommodate a lot of hanging items. http://www.greengatewoodworks.com/gladwyne-linen-closet-1 daily 0.75 2019-02-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549033048038-GJ2OWEIGKVH1841EPS8O/IMG_0681.JPG Gladwyne Linen Closet A client in a small 1830’s home in Gladwyne had done some renovation work closing off an old stairwell opening to create closet space in the master bedroom, and as a result this small alcove was formed in the upstairs hallway. She asked me to create a linen closet to utilize the space for more effective storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549033047129-9LAQVAX0BGZSTNLUNWHR/IMG_0679.JPG Gladwyne Linen Closet The finished linen closet. The doors and drawer fronts all have a squared off raised panel design to match the doors on either side leading to the bedrooms. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549033047124-UVUYMV28R7R8B5OZ9CFK/IMG_0680.JPG Gladwyne Linen Closet Inside the upper area is ample storage, and on top of each adjacent doorway is a small silicone bumper to keep the linen closet doors and the door trim from damaging each other when the doors are opened. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1549033048182-MV1SGHIWCDX0V6LOZOEZ/IMG_0682.JPG Gladwyne Linen Closet Three large maple drawers provide plenty of storage space below. All the drawer boxes are made from solid maple with housed rabbet joints in the corners, which are reinforced by the black walnut pegs. Each drawer is on a soft close undermount slide for smooth operation. http://www.greengatewoodworks.com/my-own-builtins daily 0.75 2019-02-16 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316445112-8DWLW6UDE8OXFJD17I9D/Campbell+Built-In+2-2019+IMG_4507+-+lightened+floor+fixed.jpg My Own Built-Ins This is a set of built-ins I made for my personal home. Designing your own project affords the luxury of taking your time with the design. As with most of my built-ins, the countertops and doors are made from solid maple; however, there are many hidden features in this piece, born out of many discussions my wife and I had about how these built-ins would work best for our family. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316443218-HCW473VSHA4W5QTXCZZD/Campbell+Built-In+2-2019+IMG_4481.JPG My Own Built-Ins A closer shot showing the maple countertops and the trim details. The center cabinet sits forwards from the side units to create some visual interest. Since the upper shelving units are set back from the lower cabinets, it made for an interesting transition where they all came together, especially in the curved front edge of the countertops. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316443756-08WSZR9LISH1Q789ZAXD/Campbell+Built-In+2-2019+IMG_4489.JPG My Own Built-Ins The left-side doors conceal an existing radiator behind a false cabinet front that swings open to provide access when needed. The arched baseboard lets air in to the radiator, and the open mesh doors allow heat to flow out to the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316443575-FDN59TIIGAKYKVWROBBN/Campbell+Built-In+2-2019+IMG_4487+wires+removed.jpg My Own Built-Ins Here you can see how the false cabinet front opens up. When closed, a hidden magnet helps keep if firmly in place and makes the joint where the pieces come together almost invisible. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316444017-AB3SZS7UPODSQBLFWAY8/Campbell+Built-In+2-2019+IMG_4501.JPG My Own Built-Ins The lower cabinet on the right side has the same mesh doors, but to keep the kids’ toys hidden, I added a dark plywood backing. Both the center and right lower units have a dark trim board hidden behind the arched baseboard to keep toys, etc. from getting lost under there. The low shelf beneath the TV helps minimize the look of the components and conceals the various cables. Outlets located near each window are split between standard outlets and our holiday light circuit for candles at Christmastime. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316447898-ADRJIU7O96CELF2Q9RDK/IMG_0914.JPG My Own Built-Ins Instead of doing more traditional crown molding, we decided not to build the upper units to the ceiling so that we could carry the existing window trim across the top as a design detail. This allowed us to add another hidden feature: a long strip of dimmable LED lights hidden behind the top trim which provides a nice glow in the evenings. That glow didn’t show up well in our professional pictures taken during the day, but I managed to get a decent shot with my phone one evening. Wafer lights are concealed above each window for additional light. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316447379-3XND7WDSCCKR61NWWI1R/IMG_0054.JPG My Own Built-Ins The last two photos show what we started with and where we ended up: a mish-mash of old furniture and storage units…. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1550316444631-PNVC4AJA4ETRX8MD5AIS/Campbell+Built-In+2-2019+IMG_4507+-+lightened+floor+fixed+-+cropped.jpg My Own Built-Ins …and now a set of functional built-ins that provide all the storage and ambient lighting we need in one package. To see more pictures of my personal home, click here. http://www.greengatewoodworks.com/tree-bookshelf-1 daily 0.75 2019-03-11 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1552267162156-45RVEQ64W18T6RVT7NAI/tree+bookshelf+rough.jpg Tree Bookshelf My daughter’s kindergarten class was having a fundraising that my wife was involved in, so she asked me to put something together for them to raffle off. The theme was “Reading” so we came up with this tree-shaped bookshelf idea. As it was a side project, I don’t have a lot of progress photos of it, but this is it in it’s rough state. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1552267171778-U1PLYOVUG8KC2BUPR0LZ/Tree+bookshelf.jpg Tree Bookshelf The finished shelf with some of the books that went along with the total package people were able to win. The wide base gives it excellent stability, and the laminated design of the shelves gives them a lot of strength. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1552267179757-86TP0OJBBZJG8UY41GPS/Bluebird.jpg Tree Bookshelf I also made two small birds to go along with the bookshelf. This one is an Eastern Bluebird. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1552267165139-KITTJO133SS6NNKU81GQ/Goldfinch.jpg Tree Bookshelf The second bird is a Goldfinch. http://www.greengatewoodworks.com/small-bar-cabinet-1 daily 0.75 2019-04-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145006422-X5OSTECS1F4Q1WONTD52/IMG_1494.JPG Small Bar Cabinet A client had this small alcove that she wanted to use for a bar cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145006639-2XBV8OVY6D4KT0V2NYZC/IMG_1497.JPG Small Bar Cabinet There had been a corner cabinet that hung over into the alcove, so I packed out the walls to create more wall space for it to sit against. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145015151-D60HNXYNAAC8X1W9GQ8E/IMG_1513.JPG Small Bar Cabinet After hanging the drywall, I got the cabinet and countertop fit into the new space. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145027520-9IJERZLJOI9FEOB7RO6O/IMG_1534.JPG Small Bar Cabinet Installation of the inset flat-panel doors. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554145052091-JHGDBC7TB72DY8N3775B/IMG_1556.JPG Small Bar Cabinet The finished space with custom baseboards I made to match the existing ones, and the corner cabinet in its new home. I used hammered antiqued brass knobs for the cabinet to match the hardware on other pieces of furniture in the room. http://www.greengatewoodworks.com/cedar-platforms-1 daily 0.75 2019-04-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554146525723-Q06J7JMDQA7DBQW2J8O5/IMG_1336.JPG Cedar Platforms I got an unusual request from a long time client to make up some cedar platforms for an outdoor space at her vacation property. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554146562328-F85TSWR5BPGPG0Z5XTZH/IMG_1341.JPG Cedar Platforms One of the completed platforms They’re all made from tight knot wester red cedar wrapped around a pressure treated frame and secured with stainless steel screws. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554146595511-RL6OCX51K6VQFZWKN8IJ/IMG_1348.JPG Cedar Platforms The five completed platforms. They will serve an a platform for a tent or for kids to play on. Each one has stainless steel hardware to link them together securely, and they are notched to drop into an existing wooden framework at the property. The client opted to oil them herself, so I left them sanded and ready to be finished. http://www.greengatewoodworks.com/spalted-maple-floating-shelves-1 daily 0.75 2019-04-01 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143557622-FE4B90S8FWJUXCE4OPZQ/IMG_1085.JPG Spalted Maple Floating Shelves I had some left over spalted maple from this job, and the client asked me to create some floating shelves for her living room. After cutting them to rough sizes, the next step was to fill all the small wormholes with epoxy before sanding them down and coating the shelves with a wiping varnish. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143580114-1HOL7J4CXTZI9EINDCQX/IMG_1519.JPG Spalted Maple Floating Shelves I removed some small sections of the existing walls so I could slip in some framing pieces to help strengthen the shelf brackets. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143640033-JXON1ALQIMPJDL0KQD7L/IMG_1557.JPG Spalted Maple Floating Shelves The shelves installed in their final home. They are evenly spaced on either side of the tv, but the lower shelves run long to allow for placement of taller items. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1554143655063-K5KXBEEP6OJ1JX2JLU9U/IMG_1564.JPG Spalted Maple Floating Shelves A side view showing the depths of the shelves. http://www.greengatewoodworks.com/steve-morrisons-batmobile-bed-1 daily 0.75 2019-10-27 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288797557-R4APK9JBC99VX8LV1G96/IMG_1272.JPG Steve Morrison's Batmobile Bed Today (June 13, 2019) I can reveal a secret project I’ve been working on for the past few months: a Batmobile bed I made for Steve Morrison of The Preston and Steve Show on 93.3 WMMR as a surprise for his birthday. Steve is fairly obsessed with superheroes, and Batman in particular. One day they were talking on-air about how he should really have a Batmobile bed, so I wrote in and offered my services. After sketching up a few different ideas based on this toy model, I settled on one and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288790018-LW5UEJ0Z1FLYZ3SQ4QCL/IMG_2289+-+with+watermark.jpg Steve Morrison's Batmobile Bed Here is the completed Batmobile bed in my shop. Based upon the Batmobile from the original 1960’s Adam West TV series, it has working headlights, Bat-rays on the front of the car (those yellow lights next to the headlights), a rocket booster in the rear, and a “P+S” Bat-signal that shines on the ceiling. Sized for Steve’s queen-sized Sleep Number mattress, it measures 11’-6” long by 5’-10” wide. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288780404-9Y5PFUK3YIGDCN88BNN9/IMG_2281+-+with+watermark.jpg Steve Morrison's Batmobile Bed A closeup of the Bat logo on the side rail of the bed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288785982-DLJKLMKN3HYG3WZM9CQ9/IMG_2285+-+with+watermark.jpg Steve Morrison's Batmobile Bed A close up shot of the back of the car and the rocket booster. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288785754-3PGP8FM6R0IQCGF0L5VS/IMG_2284+-+with+watermark.jpg Steve Morrison's Batmobile Bed Red LEDs inside the rocket booster give it a warm glow. The license plate is a copy of the one on the original 1960’s Batmobile. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288782802-0KMJQKL7T8GP2XS3CJ08/IMG_2282+-+with+watermark+on+side.jpg Steve Morrison's Batmobile Bed Me, holding a piece of plywood to demonstrate the Bat-signal in action. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288787284-T0SM1YGCQ3Z230G12CVH/IMG_2286+-+with+watermark.jpg Steve Morrison's Batmobile Bed A close up shot of the headlight assembly and the Bat-ray. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1560288789744-0KHV80OBVDCQ8KRGEBPA/IMG_2288.+-+witih+watermark.jpg Steve Morrison's Batmobile Bed Here is another wide shot of the completed bed. This was a really fun project, and I’d love to make more like it in the future, so contact me with your exotic bed ideas, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1567433111882-XQZQLV35G5JXSZJDHMRY/Steves-Batmobile-Bed-Surprise-25.jpg Steve Morrison's Batmobile Bed https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1567433154608-KM9XMIT2GPTA3ZUGD9U1/Steves-Batmobile-Bed-Surprise-36.jpg Steve Morrison's Batmobile Bed Steve taking a test drive. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1567433158706-1A3QY1NT9OQU2FLZYY33/Steves-Batmobile-Bed-Surprise-33.jpg Steve Morrison's Batmobile Bed Steve and I in studio. Below is a video of the on-air reveal from Preston & Steve’s Facebook page. http://www.greengatewoodworks.com/narberth-built-in-closets-and-window-seat-1 daily 0.75 2019-11-20 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574216461073-2RKNPU4PBRAFVEK4G6AX/IMG_8964.JPG Narberth Built In Closets and Window Seat A client contacted me to create a built-in window seat and a pair of storage cabinets for this unique space in their daughter’s room. This was the space before I started. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574216462642-YLLR0GVPYKHWIF6NPP1T/59518971444__10FE5155-E941-4492-BEC6-42E4C11F195E.JPG Narberth Built In Closets and Window Seat After building and priming the cases in my shop, I took them to the site and installed them. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574216466642-X9XZN0G60HQL5K00CM9G/IMG_9051.JPG Narberth Built In Closets and Window Seat Next up was fitting and hanging the doors and drawers. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1575923619263-OCC3YWBW5JDE1Y57D2NA/9CE681E8-6F46-428F-9499-926C0659FB68.JPG Narberth Built In Closets and Window Seat A picture of the finished project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1575923619205-LLCNUY1NFTDL5EU8GI8K/DD060E0E-253F-4E83-8B9D-BCC86B34B90F.JPG Narberth Built In Closets and Window Seat The left side cabinet provides storage for bins and smaller items, while the right side cabinet provides hanging storage for clothes. http://www.greengatewoodworks.com/narberth-living-room-builtins-1 daily 0.75 2019-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527743071-R9ECNHBJGVRH6T5USLV5/IMG_8742.JPG Narberth Living Room Built-ins This client’s living room wasn’t used much by the family because it was a dim space. There was only a single overhead light, and most of the natural light was blocked by a large wrap-around porch. They also had an extensive collection of books they needed storage space for, so I came up with a plan to address the different issues. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527746908-3VXUDGFTOBD2EBOXD0HL/IMG_8746.JPG Narberth Living Room Built-ins The installed lower cabinets. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527756049-WEXZ830NIPMD6F6S3FA4/IMG_8806.JPG Narberth Living Room Built-ins After I had fabricated and finished the maple countertops, I installed the upper units. Next up was the trim and finishing touches. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527738860-C0S7VADB0PE4P5YFX0UL/FD176326-6A86-416F-A0F9-9D5790176EA5.JPG Narberth Living Room Built-ins The finished project features custom crown molding to match trim in the home, chamfered columns, inset raised panel maple doors, and lifted baseboards. Darkened boards behind the baseboards make sure nothing gets lost underneath. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574527738711-VDXH2D1J2SXKPQRX5NHN/E05AD183-C83D-4076-B716-3B253FA5AB14.JPG Narberth Living Room Built-ins LED strip lights under each shelf and along the top of the unit add extra light to the room, making it a far more usable space. http://www.greengatewoodworks.com/standup-paddleboard-1 daily 0.75 2019-11-22 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380300762-MTBPSEI3DUT0QBM8AKCM/IMG_0298+2.JPG Stand-up Paddleboard Back in 2016, I decided to make myself a wooden stand-up paddle board because I wanted one and it would also be a challenge to make something new. I did some research online and found that Paulownia, considered a weed tree in our area, is one of the best woods for this sort of project. After searching around a bit, I found a place where I could get a few Paulownia logs and had them delivered to my house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380301839-AZXYDO9MTBJALFSYQV5V/IMG_0301.JPG Stand-up Paddleboard The first step was to mill the logs with my alaska mill to cut them into thick planks. Then they were stacked and set aside to dry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380307027-OAAMLLQ2VGD6CCPVTWAP/IMG_6952.JPG Stand-up Paddleboard Three years later in August of 2019, the wood was finally dry enough to use. It takes about a year per inch of thickness to dry, so I knew what I was in for from the start with this project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380308749-JJOZCODCYXE39V9D7A9J/IMG_7001.JPG Stand-up Paddleboard Using 3/4” plywood, I made up a rocker template that was the approximate profile of the paddle board. That was then used to mark out pieces to be cut out from the larger planks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380314741-7MBWU4CJB2NU2NFDZ7OE/IMG_7324.JPG Stand-up Paddleboard After cutting out enough pieces, I tacked them together into a large blank. All the boards were screwed together except for the center joint which was lightly glued. This was the best way to assemble the blank because it will need to be disassembled in a later stage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380317775-PNQ0DKQHNCDUQGBTXX8Z/IMG_7335.JPG Stand-up Paddleboard Using a template I found online, I laid out the overall shape of the paddleboard. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380319408-WX3QZHVD3LEX2M42CHBV/IMG_7338.JPG Stand-up Paddleboard I used a jigsaw with an extra long blade to trim off the excess material, and at that point it really started looking like something. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380321442-P20SDSS88LHT7E73BGFH/IMG_7346.JPG Stand-up Paddleboard The next step was to shape the rails of the board using a power planer. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380323841-MDL9NBDI8N0ML4207ERU/IMG_7355.JPG Stand-up Paddleboard After the rails were shaped, I used a random orbital sander to sand the blank down to a rough shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380324506-AAEGBO8CMFTU36P7F0X9/IMG_7498.JPG Stand-up Paddleboard Next I carefully broke apart the center joint of the blank (the one that had a small amount of glue holding it together). After that I removed the screws holding the rest of the blank together and separated the individual boards. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380329104-NB9IGW3XID0IU1GVDUZV/IMG_7504.JPG Stand-up Paddleboard I marked each board with a sharpie to show where material could be removed to reduce the overall weight of the paddleboard. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380334657-SWNZCE15XJRK6IRM1V34/IMG_7512.JPG Stand-up Paddleboard This was the end result after I removed the interior material. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380337732-TCNASUIMNPE58DW8S2GY/IMG_7513.JPG Stand-up Paddleboard The chambers of each board were offset from the next board to create one large chamber inside the paddleboard, while leaving enough vertical “posts” inside the chamber for structural support. Areas for a recessed handle and finbox were left solid so there was an area to mount them in later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380342128-RO82KP9CREBPAZDZ9WWX/IMG_7533.JPG Stand-up Paddleboard After chambering each board, I glued them back together and clamped up the entire assembly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380342639-R70UQ9AK52Q0W9W0GOSE/IMG_7717.JPG Stand-up Paddleboard Once the glue had dried, I sanded the blank down to it’s final shape. The dark strip on the bottom of the board in this picture is a low area that had to be stained and filled with epoxy prior to final sanding and staining due to a natural defect in the wood. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380346358-94Z66M1A29ZWON5832WS/IMG_7718.JPG Stand-up Paddleboard After a few coats of stain, the paddleboard was ready to be fiberglassed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380351971-P6P98TK7JR7XVBDYF5EF/IMG_8140.JPG Stand-up Paddleboard Prior to applying the fiberglass, I installed the finbox in the bottom and a recessed handle in the top (shown here masked off with green tape). I also wanted to add in my company logo, so I printed it out on rice paper which will turn clear under the fiberglass coat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380353553-ZOEZGA78FZGTOPLK9ZLF/IMG_8141.JPG Stand-up Paddleboard This was taken after the first fiberglass coat, and you can see how the rice paper disappeared exactly as planned. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380358003-FUA6LNB1PUHF9MEUKUGR/IMG_8161.jpg Stand-up Paddleboard A close-up shot of my logo on the paddleboard, taken after multiple epoxy coats and some final sanding. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380361533-BSKE717A0PB3MS6QT63W/IMG_8230.JPG Stand-up Paddleboard After installing the fin in the finbox, it was time to test it out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380367975-6SUELK75DXPWROV5O18L/IMG_8401.JPG Stand-up Paddleboard Fortunately I have some friends nearby with a pool who were willing to let me do a “test float” to make sure everything worked properly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380367234-ZAZJDWGI613HAX7U7URN/IMG_8399.JPG Stand-up Paddleboard Another picture from the test float. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574380293350-NW7EM4MWCF567POP8KXU/BBE280FF-D5E6-4AEF-8BC4-AE144208D055+2.JPG Stand-up Paddleboard Overall, this was a very fun and challenging project and I’m looking forward to many years of taking this out on our local lake for my morning exercise. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770838564944-IGFGF34WT59FV6QGUBWR/IMG_1514+2.JPG Stand-up Paddleboard This is a photo of me out on the paddleboard getting my morning exercise one very foggy morning in July of 2025, taken from the western shore of Marsh Creek State Park by Ed Harding. http://www.greengatewoodworks.com/lego-house-1 daily 0.75 2019-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523539712-C4HNMTIZO4HT9BQHI4ZJ/IMG_1483.JPG LEGO House This one is a little different than my normal projects. I’ve been playing with LEGOs since I was a kid, and now my kids are into it too, which is good because it gave me an excuse to create this scale model of our house “for the kids to play with.” https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523538099-NJTXVV79E36IVKY3K89V/IMG_1482.JPG LEGO House https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523535030-J4WWZQS3YPS1IPVEQMKA/IMG_1479.JPG LEGO House https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523744207-8ZKE0M6Y2MCC91VU7SUB/1D3EF40A-C65C-4B4D-9378-8B7F822F13F1.JPG LEGO House https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523529274-FTLZWQQKDVKQTBHJZXBL/IMG_1475.JPG LEGO House I hinged the front wall of the house so it could open up like a doll house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574523527788-INS0139I4Y1UFT0FX60R/IMG_1472.JPG LEGO House I also made up LEGO figures for my wife and I, and both the kids. http://www.greengatewoodworks.com/berwyn-pergola-1 daily 0.75 2019-11-22 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383472313-8OK0WZ3UU0HBKTMU74IU/IMG_7664.JPG Berwyn Pergola A job came to me to create an outdoor pergola that was designed by Hess Landscape Architects. I ordered these western red cedar boards to fabricate the project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383449910-MC3BENR8I1GGE30YE9PN/8E173500-E54A-4FD7-9D18-118F5285DB51.JPG Berwyn Pergola The pergola contained multiple arches all based on a central point, so I made up a simple plywood trammel that would allow me to lay out all the arches at once to make sure they all fit together properly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383449150-YR922R9SMFUGE3TYI2KY/5F51FE0A-D57A-42A1-B64E-4F6AA9B726A9.JPG Berwyn Pergola After cutting out the pieces, I had a nice set of templates to use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383511490-PVLJKQG98B4FXNO77F2L/IMG_7922.JPG Berwyn Pergola After gluing up some boards for the larger outer posts (not shown here), I put together the smaller inner arches to create the central panel. The spacer blocks were used to keep things in place while I laid out for a radial lattice that was part of the design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383463303-YPW2SAEKF3QQM5OJSVPN/C99D9ACC-F9DC-4040-89C3-4C9920CB13CB.JPG Berwyn Pergola Here you can see the radial lattice of the central panel. All the joints were half-lapped and glued for extra strength. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383482679-9VW6GNTKIQO04SA7Z5QQ/IMG_7740.JPG Berwyn Pergola Next up I got to work on fabricating the large outer arch. Multiple layers of cedar were used to create this arch, along with a lot of waterproof wood glue. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383455076-X5GLDOU64TBUVMCZUZHX/04B806BE-89E0-4354-B73D-6E429D2C44D3.JPG Berwyn Pergola Part of the job included turning a pair of custom finials on the lathe to match ones that were on the home. I don't get a lot of call for lathe work, so it’s a fun change of pace. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383518041-IVQOOLY0PF3JLQ1JOKP3/IMG_7988+2.JPG Berwyn Pergola After fabricating the other parts and painting everything, I hauled it to the site and laid it out for final assembly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383528611-6CVQZEBMJWJ2HS7DE3ON/IMG_7990+2.JPG Berwyn Pergola A few extra hands from Doyle & McDonnell, Inc made all the difference in getting the pergola into its final position. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383534754-HTI29OIAPVNTIMVR8FUS/IMG_8997+2.jpg Berwyn Pergola After the pergola was installed and secured to the wall, I did a few final touchups. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574383457275-P33GUR6YBVPJ9WKAMRQA/01950F92-6E12-4D37-8F3C-CF874AF3BA32+2.JPG Berwyn Pergola The finished project. Design by Hess Landscape Architects, and landscaping by Doyle & McDonnell, Inc. http://www.greengatewoodworks.com/lionville-builtins-banquette-1 daily 0.75 2019-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522431794-781OVIYMT5F2N3OQ32G3/IMG_0847.JPG Lionville Built-ins & Banquette A client asked me to build a long banquette for a seating nook in an area off their kitchen, as well as an adjacent table cabinet for storage. After coming up with a design, I got to work fabricating in my shop. Here you can see the lower units installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522337459-GXBF23NT1D174JBWCVCZ/IMG_7822.JPG Lionville Built-ins & Banquette Since I do all my own work, and work alone, photos of me working are somewhat few and far between. The client took this one of me while I was filling nail holes after fitting the cabinet doors. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522391565-CRCMNFIJ1DC1H6V3LJF4/IMG_1011.JPG Lionville Built-ins & Banquette Here you can see the split top on the banquette installed and opened. Inside there is plenty of room for storage of larger seasonal items. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522185474-WM1PQILY5CCJCSL7YO5R/E78D6DCA-8BC9-4580-8A18-95AAB73C11CF.JPG Lionville Built-ins & Banquette The finished banquette. The client planned to get cushions made for the top after I completed my work, so I set the height of the banquette top to account for the thickness of the future cushions. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574522185280-JE1K2BOPID6B1YCC4NLO/A447BDC4-99F9-4B4B-A0EB-35BB94064D6C.JPG Lionville Built-ins & Banquette A photo of the completed storage cabinet. The center stile on the upper portion helps to reinforce and strengthen the shelves. http://www.greengatewoodworks.com/narberth-bedroom-builtins-1 daily 0.75 2019-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528947404-5WX8KSIDMGWMUA0ONRCG/IMG_8750.JPG Narberth Bedroom Built-ins While I was building these living room built-ins, the client asked me to also make a set for their master bedroom to provide additional storage for their extensive book collection. Originally this wall was blank except for a dated radiator cover. In this picture, the radiator cover has been removed and the lower cabinets installed. Normally I build my cabinets in the shop and attach the face frames there prior to installation, but in this case the stairwell access to this room was so narrow I had to bring the cabinet cases up in pieces and assemble them in place, and then attach the face frames later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528948019-ALKMVFPYFDX3RBLNMLU5/IMG_8774.JPG Narberth Bedroom Built-ins Here, the face frames have been installed, along with the new radiator cover and maple countertops. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528955048-LXA93AAMY3Q7763GIRH2/IMG_8776.JPG Narberth Bedroom Built-ins The upper cabinets installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528973863-O3M2RH9UKT8GZDZ98B33/IMG_8935.JPG Narberth Bedroom Built-ins After the trim was installed, it was ready for final painting and touchups. This unit also required custom crown molding to match the existing trim, so I fabricated that in my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574528997920-NTFCR4CA7AG9F3QX12Q3/IMG_9090.JPG Narberth Bedroom Built-ins The finished product. The lifted baseboards have a darkened board concealed behind them to keep any small items from getting lost back there, except for the center area. That central area is left open to allow air to flow in to the radiator so it can be heated. http://www.greengatewoodworks.com/mothers-day-birds-1 daily 0.75 2019-11-22 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574446097617-PJNL64MU06Y7XI6GG6BG/IMG_1624.JPG Mother's Day Birds After I had made this bookshelf for my daughter’s kindergarten class fundraiser, the teacher asked me about making some more birds for another project. Using plywood scraps from my Batmobile Bed project, I laid out as many birds as I could using a template i had made previously. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574446113457-DDXUOR84L79AUL8QOULJ/IMG_1639.JPG Mother's Day Birds Using my bandsaw, I cut out all the pieces slightly larger than the patterns I had drawn. After this I joined up 2 pieces to make each bird, then glued and clamped them together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574446097465-CFHUKYNRTZZ9II0ZLO26/D527B441-B202-4162-86BF-1A50DE4DB99E.JPG Mother's Day Birds The sanded birds in a box, ready to be delivered. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1574446191548-XFI1PM82I9AECL35Z72Q/IMG_2339.JPG Mother's Day Birds A few weeks later the kids had painted the birds up and they were ready to be presented to all the Moms. http://www.greengatewoodworks.com/our-mudroom-lockers-1 daily 0.75 2019-12-16 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508332921-4IOL6VACYSL0PFU10OGX/IMG_8530.JPG Our Mudroom Lockers My mudroom was lacking proper storage for coats, book bags, etc, so I decided to make a set of lockers for my wife, myself, and my two daughters. I had installed a reclaimed brick floor in that room a few years prior, so when I built the lower case for the lockers I had to scribe it to fit the fairly uneven surface of the bricks. Here, you can see the lower locker case upside down after the wavy scribe cuts had been made. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508333193-6HC4N8PA65FFWDKK0H04/IMG_8532.JPG Our Mudroom Lockers Here you can see how the scribe cuts fit in with the surface of the bricks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508338395-WRP6XVECX840BOD18OXP/IMG_8535.JPG Our Mudroom Lockers A wider shot of the installed lower case. The hooks in the background (and another row up higher out of view) are what we had used prior to this for hanging coats, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508341162-E8UY78EV9K5PBTC6X0UJ/IMG_8547.JPG Our Mudroom Lockers Next up was milling some black walnut planks to make a bench top. After I had them roughly planed to size, I played around with which sides to join up until I was happy with the look. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508327843-ASGC2C3X9F9PAMO5H3GL/377DB8F8-17FD-4F31-AA63-23042F998CC1+2.JPG Our Mudroom Lockers This is the finished top after it had been fit to the space, sanded, and then coated with a satin polyurethane. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508346426-UZ4Q5GGY1R4RUR1RA55S/IMG_8590.JPG Our Mudroom Lockers Next up was installing the upper units. After this it was on to face frames, end panels, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508328395-5NR59M611MJP488HC8Y7/E1A84AC7-EA57-48EE-ABCB-A5FEEB979240.JPG Our Mudroom Lockers Here my helpers are keeping a close eye on me and asking a million questions while I touch up the final coat of paint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508405620-MTMX25UD1WPM04NSULVN/D4EDB04D-BF60-43B1-A35B-942930102A64.JPG Our Mudroom Lockers I designed the upper area of our lockers to have a smaller cubby section for storing smaller items, hats, gloves, etc. My wife and I were unable to find baskets we liked for the space, so I created this apple crates from some reclaimed pine I had in the shop. Each one also got a clear plexiglass insert on the bottom to keep anything from falling through the cracks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508322317-DWQV5WOPFJ0UH8N0KPBB/69BF6401-8481-4FF6-9E24-30CB4D9FE09C.JPG Our Mudroom Lockers A finished shot of the completed project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508323506-JBQSBTVD4GN8AHEN3WNG/0443C519-3F93-432E-BED0-921919A6494B.JPG Our Mudroom Lockers Each locker also got an authentic locker number courtesy of my father-in-law who worked for Penco Products. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1576508324772-6IBP5JAQ7BO3W0E7OOF0/45083128-774E-463D-8FBD-3DA0D7F07182.JPG Our Mudroom Lockers While I was putting in the lockers, I also finished up this taller shelving unit I had made previously for the other side of the room. Using a cutoff from the locker bench top, I put in a matching black walnut seat over our radiator. http://www.greengatewoodworks.com/reclaimed-barn-beam-mantle-1 daily 0.75 2020-01-25 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579952397279-B2AN5O8OUNN06V53JH32/IMG_9200.JPG Reclaimed Barn Beam Mantle A client commissioned me to create a new mantle for their living room from one of the antique reclaimed red oak barn beams I had in stock at my shop. I cut it to length using a handsaw to create a historically accurate look for the end of the beam. Then I got to work hollowing out the back of the beam to reduce the overall weight of the mantle so it would work with the existing mounting hardware the client had in place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579951742524-ZUFG2VTCA7LGWQQLFIQC/IMG_9486.JPG Reclaimed Barn Beam Mantle After lightly sanding the beam and finishing it with a satin polyurethane, I test fit the beam in place. It has original mortise and tenon joinery still intact, as well as cut marks on the face from when it was hand-hewn 100 to 200 years ago. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579951772598-8GBVSCQY9JIGZ6YOWJM4/A2FA6D0C-1C49-4ECC-9727-ED00DBBFDE48.JPG Reclaimed Barn Beam Mantle A picture the client sent to me of the finished mantle decorated for Christmas. http://www.greengatewoodworks.com/craftsman-style-china-cabinet-1 daily 0.75 2020-01-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179142795-5CX0THIDNUACTC20BGHW/IMG_9829.jpg Craftsman Style China Cabinet An old friend of mine had picked up a pair of antique doors and asked me to use them to create a piece of furniture for her. Since it was going to her home in Syracuse, New York, it seemed only fitting that we go with the Craftsman style popularized by Gustav Stickley in Syracuse in the early 20th Century. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179142856-0U1Z3FXZ2HZB8FZ986MI/IMG_9830.jpg Craftsman Style China Cabinet This piece is based on and inspired by Stickley’s #815 china cabinet. It has solid quarter-sawn white oak in the frame, with flat-sawn white oak panels for contrast. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179143897-1GUXR1LZOLRWRLY6RAMM/IMG_9831.jpg Craftsman Style China Cabinet Inside the cabinet are three adjustable shelves, also fabricated from quarter-sawn white oak. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179143894-89AI1J3TCQY17DQSKM2K/IMG_9832.jpg Craftsman Style China Cabinet I opted to go with a sawtooth adjustable shelf system to maintain the antique character of the piece. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580179144724-VKTX4S7C82R9P3P1PW43/IMG_9833.jpg Craftsman Style China Cabinet The door latch and catch hardware were original to the doors and were refinished for this project. http://www.greengatewoodworks.com/philadelphia-builtins-1 daily 0.75 2020-02-11 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386035578-NSQYTZ27Q61G7TAKQHBC/FA4C0FBD-B28D-4EF8-9B24-3E086F890CCC.JPG Philadelphia Built-ins A client contracted me to create built-ins on either side of their existing fireplace. This is the before picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386051498-6T2A9XH4SJ68I5IRIR5L/IMG_9849.JPG Philadelphia Built-ins The client chose to have two live-edge white oak countertops installed for this project. This is the left side countertop during fitting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386051546-MXCVYHBXDPSQYQV6FY7O/IMG_9880.JPG Philadelphia Built-ins Setting the upper units. Next up was installing LED lights behind the shelves and fitting column details. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386060309-XPNGUQ4G5W22WVUSFX4X/IMG_9908.JPG Philadelphia Built-ins The columns were scribed to fit exactly against the existing fireplace stone. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1581386039718-L4QXOPQF0VK7T7DKXYYM/5063F26D-2B4F-4AC8-B1A1-7051A77E6767.JPG Philadelphia Built-ins The finished project. The LED lights cast a soft light into the room, while the cabinets provide additional storage and visual depth for the room. http://www.greengatewoodworks.com/reclaimed-red-oak-coffee-table-1 daily 0.75 2020-01-25 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579953692366-QGNJ5WSJZTCVCV0P15VQ/IMG_9168.JPG Reclaimed Red Oak Coffee Table A client approached me to create a coffee table for his girlfriend as a surprise present. I milled up pieces from some of the reclaimed red oak barn beams I had in stock at my shop, and then assembled the base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579953733692-A2ECH78VUXYI8I1T6X03/IMG_9805.JPG Reclaimed Red Oak Coffee Table The finished table in it’s final home. The top is a piece of marble that has been passed down through the client’s girlfriend’s family for generations, and it pairs perfectly with the barn wood. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579953737468-856R51IRJXRQ2BHE0RGT/IMG_9807.JPG Reclaimed Red Oak Coffee Table The barn beams this wood came from were 100-200 years old. Holes from the original draw-bore joints are visible in the piece as well as staining from the original iron cut nails. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1579953731560-BGNMS5SYMCGGYL2UTF1Y/IMG_9804.JPG Reclaimed Red Oak Coffee Table One more finish picture with Mabel the cat. http://www.greengatewoodworks.com/black-walnut-serving-boards daily 0.75 2020-01-31 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1580503357480-I5E3WYJBKBDFNZT321YR/77D23A44-2831-4FA4-896D-E2E9C0307973.JPG Black Walnut Serving Boards This trio of black walnut serving boards were made as Christmas presents in 2019. Each board was 18” long by 13” wide by 1-1/8” thick with a large hole that fits an oven-proof Le Creuset mini round cocotte. The post can be used to hold dips, etc. and rest on their handles, so they don’t scorch the tabletop below if they’re hot. http://www.greengatewoodworks.com/giraffe-bookshelf-1 daily 0.75 2020-03-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1583708953359-EOCYELG9NM9LPUWKOUZI/E1C19A92-3621-431E-BBA4-75FCF6A788B5.JPG Giraffe Bookshelf This was a set of giraffe and tree bookshelves I made as part of a fundraiser for my daughter’s nursery school. The pair of bookshelves fit together to show a hungry giraffe nibbling on a tree. For smaller spaces, the bookshelves can be displayed apart. The design is also reversible, allowing for even more options. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1583708953307-WDWEP2H2XSV58HX69ZYJ/C9A2E89C-933C-4CF1-AAA9-D8BB8DB0FAE2.JPG Giraffe Bookshelf The giraffe is painted in a cheery bright yellow and has brown accents on its hooves, mane, tail, and ossicones. http://www.greengatewoodworks.com/penn-valley-hutch1 daily 0.75 2020-06-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621437365-1SELQBMXZJGIZUVF8SQY/IMG_0865.JPG Penn Valley Hutch I created this built-in hutch for a client who wanted to replace an existing kitchen desk in order to gain more usable storage space. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621437783-IB3KHAM7C428G9S9BPQ4/IMG_0866.JPG Penn Valley Hutch The lower cabinet has two standard drawers and four pull-out shelves. The upper cabinet sits atop a solid black walnut countertop and has several shelves for additional storage and spice racks attached to each door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621442853-CV6I93X82IHUDIA6MH2V/IMG_0868.JPG Penn Valley Hutch The spice racks are made primarily from maple with 3/8” dowels in front of each shelf. The four upper shelves are designed to hold small spice jars, while the three lower shelves are set up to accommodate larger ones. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621684496-YUSO44WP0PXS90Y8BGCT/IMG_0872.JPG Penn Valley Hutch In addition to the cabinet, I also built this charging station as part of the project. The rear area is for sorting mail, while the front slots hold phones and tablets for charging. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1591621684975-IMY9SL096ABL9ANK7LGP/IMG_0873.JPG Penn Valley Hutch The upper charging area opens up to access a hidden power strip concealed in the back. All charging cables can be plugged into this strip, which is then plugged into a standard wall outlet. http://www.greengatewoodworks.com/squirrel-mailbox-1 daily 0.75 2020-07-30 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596132572891-99R8COS4QNHCTIO6901Q/IMG_0567.JPG Squirrel Mailbox My cousin had bought a tiny picnic table to act as a squirrel feeding area to entertain her grandson, and she mentioned also needing a mailbox, so I put this together for her one afternoon. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596132563397-MC4Z2J47O9GVKGGWR4GI/3539CE3A-6D9B-4CD1-875C-83157E3F6039.JPG Squirrel Mailbox The mailbox is made from black walnut, with maple for the post and base. The small functional flag is made from a thin piece of plywood. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596132566697-JD6F2F8DDQEKX86IMDS2/IMG_0564.JPG Squirrel Mailbox The door opens on a small hinge concealed below, and the inside of the mailbox is hollow to allow for small notes, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596132563414-01ZHMFWO69MP1PVK8VGG/8733348D-5014-46C9-8C79-5BA8395D6F9F.JPG Squirrel Mailbox Luckily we had this squirrel finger-puppet on hand for the photoshoot. http://www.greengatewoodworks.com/media-peninsula-1 daily 0.75 2020-07-30 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133794547-I9FK1GE9N6BQ215XBN00/IMG_1179+2.JPG Media Peninsula A client asked me to make them a peninsula for their kitchen, with a wooden top made from some of the reclaimed barn beams I had in stock at my shop. The countertop is 3” thick, and approximately 48” wide by 60” long. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133817418-B6ALVOPY6X5JPF315KW1/IMG_1184+2.JPG Media Peninsula The barn wood is around 100-200 years old and has a lot of character. In order to maintain that character, I recommend to my clients that we only clear coat the wood, instead of staining it. Here I was using a quick application of mineral spirits to check the color of the final piece once a clear coat was applied. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133831719-JVG0VW1ML2OTL2J7IH3G/IMG_1392.JPG Media Peninsula This countertop was extremely heavy, and since I work alone I had to come up with a way to safely move it into the house. Using some pneumatic wagon wheels I had leftover from another project, I put together some quick dollies to make my life a little easier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133843493-45CZVJB8S9O9MFN2YXIN/IMG_1414.JPG Media Peninsula The peninsula installed. The base cabinet is painted a satin black and has bookshelves on one end for cookbooks, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133838393-UVNSXDGIS8HN1L7MOLCC/IMG_1408.JPG Media Peninsula The main cabinet area has double doors on each side that open for easy access to the interior storage area. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1596133844530-6UEA4X2XS4SAWGDZSISW/IMG_1447.JPG Media Peninsula The finished top overhangs each side to allow for seating along each of the long sides. http://www.greengatewoodworks.com/bottle-cap-table-1 daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606168022883-3H9SUCB60E0T6AWJD1T0/62094950819__16FE8DDF-1A9E-4504-85CA-4643E63DE802.JPG Bottle Cap Table During the summer of 2020 I was laid up from foot surgery and couldn’t work. There’s only so much sitting around I can do, so I decided to work on this project for my house. My wife had found a tall cafe table to put near our pool table, and we decided to give it a bottle-cap top. My first step was to router out the original top of the table to the proper depth, then sand it down and paint it black. After that, I began installing caps in a hexagonal pattern, working outwards from the center, securing each cap in place with clear silicone caulk. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606168029908-FOLJF14L1LBARUBLRP33/IMG_2123.jpg Bottle Cap Table After I had installed all the caps, I covered them all with an epoxy pour. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606168026803-8QV7WVLFAFAGBNEV3799/IMG_2087.jpg Bottle Cap Table A close up of the caps https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606168030445-DV2EB39BG2BC3MBCNN4S/IMG_2148.jpg Bottle Cap Table Here is the finished product. After the epoxy had fully cured, I sanded out any imperfections, restained and sealed the wood edge, and then polished and buffed the top to a gloss finish. http://www.greengatewoodworks.com/king-of-prussia-entertainment-center-1 daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606157775904-RVF6MJL5CK5AHKKCRPE3/056BA51A-B658-4E28-9BEC-BDE6CFA28C87.JPG King of Prussia Entertainment Center I didn't get many pictures along the way with this project, but it was an interesting one. The clients wanted to have an entertainment center along this wall of their living room, but the design was constrained by the long horizontal window high up on the wall. They wanted to include their TV in the design, but with an option to keep it hidden when not in use which lead us to the following solution… https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606157775908-69QVKWVD2WK68KW0UTDB/402BBCFD-CC19-4496-A3CA-445740853D73+2.JPG King of Prussia Entertainment Center In lieu of standard barn doors I came up with an idea for shallow sliding shelf cases as you can see in the picture above. Mounted on mini-barn door tracks, the cabinets glide open to reveal the TV within. They sit just above the countertop and have additional plastic pulley wheels, normally used in 3D printers, mounted along the back to keep them aligned properly and also to keep them from scuffing the main cabinets behind them. http://www.greengatewoodworks.com/ardmore-door-1 daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148344093-0EH4K9OYYL12KZ20GZP9/DA5AF746-CA16-4C30-AA07-72F7FE701884.JPG Ardmore Door A client contacted me to replace the arched entry door on their Tudor home. Besides just replacing the door, the client also wanted to add a lot more glass to the door to help brighten their foyer. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148971114-LYNNJPKXOD7XHAV4M1O1/IMG_1620.jpg Ardmore Door First step for me was making a template and laying out how all the new sections would go together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148348733-69TJ4GGUTGVVB355YKVP/IMG_1624.jpg Ardmore Door Once I had laid out for all the parts, I made up secondary smaller templates for each section. These are then tacked to the white oak lumber I milled for the door and a router is used to get each piece to its final shape. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148348933-SI1CP895IS06VHEMRQOZ/IMG_1628.jpg Ardmore Door A quick test-fit to make sure everything comes together nicely before I attempt gluing it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148352704-7MYUXSVG0W3SIL5VVPMA/IMG_1637.jpg Ardmore Door For the actual gluing-up of the door frame, I made up some plywood torsion boxes cut to fit the top arch. This allows me to clamp things together without worrying about the clamps sliding off the arched sections. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148357375-TMETV8HL4IKQ1Z995YWN/IMG_1643.jpg Ardmore Door After the glue had dried, I removed the clamps and put the original template overtop of the door to make sure had lined up properly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148357101-HISD0ZTIX8FZ33D6A1EJ/IMG_1660.jpg Ardmore Door This door was a true divided-lite door, so here I am installing the center framework for the windows. The lower floating panel has already been painted the final color. Doing this ensures the panel never reveals any unpainted areas as it grows and shrinks with the change of seasons. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148361396-VNJ07OXMIB2CVKQ2AGSV/IMG_1673.jpg Ardmore Door Inside each section I installed smaller T-shaped pieces that will hold the window panes slightly apart. Also at this stage I used epoxy to fill any minor cracks or natural defects in the wood. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148361471-E2PUTTPMD68W3Z1XOUB4/IMG_1674.jpg Ardmore Door Several coats of oil-based primer prepare the door for the final paint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148364319-8AHRYI60VYQZIPP1HQ7D/IMG_1688.jpg Ardmore Door Before installing the window panes I painted the entire door the final color to make sure there would be no unpainted spots showing through between the panes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148364963-X3JDZDKMQNTV0CIXHHC5/IMG_1729.jpg Ardmore Door Next up was installing the window panes and small retainer strips that hold them all in place. For this project I used 3/8” thick plexiglass panels because of the need for custom cutting the top angled panes. Plexiglass can be cut with standard woodworking tools, whereas glass can require more specialized tools and techniques. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148368934-9NGSUIEL2CW768CEFFUW/IMG_1902.jpg Ardmore Door I picked up a pair of these door dollies for the project. They allow you to stand the door upright and adjust it in all directions to aid in installation. They also make it a breeze to move a heavy door like this for transport. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606148342802-JJCW920GQ7U1J4LXIW9R/A673019F-D737-4D2C-96D0-BC32E7CD9EBE.JPG Ardmore Door The finished product, installed and fit to the existing doorway of the home. http://www.greengatewoodworks.com/malvern-office-renovation-1 daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161125999-G6QL8D5LT90PRYX5B1MH/IMG_3220.jpg Malvern Office Renovation This project came to me from two clients who were looking to maximize the use they could get out of their existing home office. The original setup shown here only allowed for one person to work in the room. They had in mind a large T-shaped desk which would allow them to both utilize the space, so I sketched up a design and got to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161121561-8DSGO42FALHT71NK65N1/IMG_2773.jpg Malvern Office Renovation The design called for floating shelves above the desk with built-in lights, and three lower cabinets at the ends of the desktop to allow for maximum leg-room underneath. Here you can see the lower cabinets on the far right and (somewhat obscured by my tools) on the left. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161116386-B3UKB5ND07MX6TA55TTM/IMG_2472.jpg Malvern Office Renovation I designed the desktop to be made of three large sections of black walnut. Here you can see me gluing up one of those three sections. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161121272-9W0DH61C58EP0QV6A204/IMG_2786.jpg Malvern Office Renovation Once I had the desktop sections shaped and dry-fit in my shop, it was time to install them. The first two sections would go along the wall, with the third coming in at a 90 degree angle to create the T-shaped desktop. In order to install it safely by myself, I made up an angled support to hold the two rear sections in place while I joined them on site. Then I lowered that support and eventually slid it out, allowing the partial desktop to settle into place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161126195-18T06H5501TP2GH1UHAK/IMG_2793.jpg Malvern Office Renovation Here the third section of the desktop as well as the third lower cabinet are in place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161123172-1YVQ0AWFGC3S660HBE7K/IMG_3217.jpg Malvern Office Renovation The completed desk. The lower cabinets were painted in a dark blue color which offset the color of the black walnut top nicely. Each lower cabinet has one drawer and a door for storage underneath, and the outer lower cabinet has drawers on either end and the storage space below is accessible from both ends. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161124691-QB6CRGBMXUIUH9B6AT5E/IMG_3218.jpg Malvern Office Renovation A closer shot showing the finished black walnut desktop and how the three sections come together. Custom slots were cut near the rear wall to allow for installation of the client’s monitor brackets. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606161093841-SNDEOE9HPIBX0M02S19I/IMG_3219.jpg Malvern Office Renovation Underneath the desk are two tapered legs made from solid maple. These support the desktop above as well as the embedded steel reinforcements that are used to strengthen the desktop. The floating shelves along the rear wall provide a place for components to be stored, and the panels along the rear wall are removable to allow cables, etc to be concealed. http://www.greengatewoodworks.com/downingtown-builtins-1 daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159093022-I7Z2E3YD6O31JK64JNPL/7A6EE550-B5AF-4C94-9D83-C291AD8EF1A7.JPG Downingtown Built-ins For this project the clients wanted to add built-ins on either side of their fireplace to give them additional storage and shelf space for a large collection of books. The existing mantle was red oak, and the clients were interested in having new countertops made for their built-ins from the reclaimed red-oak barn beams I had in stock at my shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159172419-86KP69Y034F2UZ5S6AQ3/IMG_1744.jpg Downingtown Built-ins I began by milling several of the beams I had at my shop and then arranging the boards for the new countertops. The clients wanted to highlight the mortise pockets in the wood from the original beams, so I tried several different arrangements of the boards to both highlight these features and to get the best flow of color across the countertop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159126980-LLC4Z88QXEZOPGPFAO9Y/IMG_2176.jpg Downingtown Built-ins Here the lower cabinets and countertops have been fit and installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159131356-RCLWEQ9FCK2IZVWLRT34/IMG_2177.jpg Downingtown Built-ins Fitting the upper cabinets was done very carefully to align with the cabinets below as well as fit to the existing fireplace stonework. The mantle was cut down to line up with the sides of the new upper cabinets exactly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159093000-G33ZECCH0ZM8R0ACETN0/26FC5EA4-B635-4327-A587-FC3C42EF83A5.JPG Downingtown Built-ins The finished product. In addition to the built-ins, I also sanded, stained, and finished the existing mantle to match the color of the new countertops. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159271809-2D1Z64NRXAUJZA0EAW3N/055C8316-111F-487B-9391-DF38C83CF7FB+2.JPG Downingtown Built-ins A close-up shot of one of the countertops to how the mortise pockets were incorporated into the design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606159094413-XNU7JVZU7XVJJUJC41FC/3431D5A1-CE8D-46D1-A20C-67735D1BD07C+2.JPG Downingtown Built-ins The pulls for the cabinet doors were made from old spigot handles the client had salvaged from their family farm. I added new hardware and custom spacers to make them function like standard cabinet handles. http://www.greengatewoodworks.com/my-greenhouse-1 daily 0.75 2020-11-24 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185083276-2ABP7ETEWMEMEIA77C5U/IMG_0812.jpg My Greenhouse When I had L.S. Stone Masonry at my house applying the exterior stone, I also had them add it to the back of the chimney that sits inside our greenhouse room. My wife and I knew we wanted to have a flat panel wainscot wall along the bottom, so I installed a stained maple top rail to give the mason’s a stopping point for their stone. Once they had completed their work I was able to get started putting in the final floors and doing the trim work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185094749-GOGLG28IP6OJ3AHLJJCH/IMG_1130.jpg My Greenhouse Our greenhouse room, along with our mudroom and laundry room, used to be where our porch was before we renovated. We decided we wanted to keep the “porch” feel in those rooms, so we designed them with tongue-and groove board ceilings and brick floors. I had already completed the floors in the mudroom and laundry room, and now it was time to install the greenhouse floors. Using the reclaimed bricks I had collected a few years earlier, I laid the amount I needed out in our driveway so I could clean them off and then pick and choose them as I worked. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185088226-NHDZRPS18E294SYBL0J9/IMG_1129.jpg My Greenhouse After installing the cement backer board, I got to work installing the bricks in a basket weave pattern. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185365319-N4HFFNFQHUFQ3YP2PCFN/IMG_1141.jpg My Greenhouse My wife wanted to help so I taught her how to lay brick. Turns out she’s a pretty decent mason. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185114334-M0ZSQCDA0UNZP0YHUKNZ/IMG_1288.jpg My Greenhouse After the bricks were installed, I sealed them, then pointed them, and then sealed the entire floor again. Sealing the bricks before pointing them allowed me to grout the joints similar to a ceramic tile floor, and it kept the normally porous bricks from getting stained from the mortar. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185115453-XDXG19YDM011UN1CQBTX/IMG_1478.jpg My Greenhouse After the floor was finished I framed up the wall and roughed in the electrical lines for new outlets. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185120166-CQ61K2N0O2SBERM4MK9O/IMG_1527.jpg My Greenhouse Next, I closed up the wall and then trimmed everything out including adding baseboards and window trim to the remainder of the room. . https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606185078946-X2B21IB6MQBJ1I6EK5SH/C592B8E8-5EEB-4629-A57D-82D75FB72CCC.JPG My Greenhouse The finished product. http://www.greengatewoodworks.com/halloween-coffin-1 daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606166346675-012IHOL2X89X8DV5OJ5D/IMG_2264.jpg Halloween Coffin This is an animatronic coffin for a client as a Halloween decoration. Here you can see the basic case and the internal pneumatic piston that opens and closes the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606166346156-HUO3XUJQMCXKIY7KAW85/IMG_2687.jpg Halloween Coffin This is the brains of the unit, hidden in a recessed area in the back of the coffin. It is controlled by an Arduino R3 microcontroller and triggered by a passive infrared motion sensor. When the infrared sensor picks up motion, it sends a signal to the Arduino which trips a solenoid that allows air to flow into one end of the piston, opening the door. After a few moments the solenoid trips back to it’s original position and air is pushed into the piston from the opposing end, closing the door. http://www.greengatewoodworks.com/plymouth-meeting-banquette-1 daily 0.75 2020-11-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160275886-0OYBIL1GI538JLWM6KHY/image1.jpeg Plymouth Meeting Banquette On this project the client wanted to create a breakfast nook with built-in bench seating. We discussed a few different options and ultimately chose an open-bottom, flat-panel banquette design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160275031-KKLV8T0GB9K7WL5YH53P/IMG_3156.jpg Plymouth Meeting Banquette Here the lower section is installed. Arched struts as well as steel reinforcement under the bench allow for the completely open base with no visible support https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160277749-ZFSS7ZMJDD2XFMUJUR1E/IMG_3160.jpg Plymouth Meeting Banquette The upper section of the bench is angled back slightly for comfort. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1606160279152-DBH02VHJ0UZJQTRKKN60/IMG_3230.JPG Plymouth Meeting Banquette The finished product, trimmed out to create the flat-panel design. Custom-made cushions will complete this new seating area. http://www.greengatewoodworks.com/chester-springs-pantry-conversion-1 daily 0.75 2020-12-04 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1607111997221-TZJBAZD05TKM9DXL20I1/IMG_6735.jpg Chester Springs Pantry Conversion This room was originally a powder room, but the client wanted to change it to a walk-in pantry instead. After other contractors were done removing some of the original plumbing and installing the new tile floor, I came in to start on my work. Here you can see the cabinets set and wiring roughed in for some under shelf lighting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1607111996493-3O3WO9I3X4CP882MUHO6/IMG_6928.jpg Chester Springs Pantry Conversion Here the counters have been installed, along with floating shelves on the left side. There is a single overhead light fixture in this room, but the client wanted to add in some additional lights, so I installed LED lights under and above the cabinet, as well as underneath the floating shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1607111998287-KFNRMNEX9QD34KQEBEP9/IMG_6966.jpg Chester Springs Pantry Conversion A closer shot of the under-shelf lighting. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1607111886211-MNQFY0HONTHTLNBJZIG3/IMG_3129.jpg Chester Springs Pantry Conversion The finished product. The counters and floating shelves are solid black walnut, there are pull-out shelves on the lower left cabinets, a pull-out trash can under the sink, and a wine fridge on the lower right. http://www.greengatewoodworks.com/malvern-fireplace-surround-1 daily 0.75 2021-05-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621280233573-KQPHH61Q2J1EQBA868TI/IMG_4822-2.jpg Malvern Fireplace Surround A repeat client had this small fireplace surround in their home, and they asked me to remove this and create a larger surround. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621280233375-IO9K8YFHCNTMXB74LPSN/IMG_4875-2.jpg Malvern Fireplace Surround The finished surround goes floor-to-ceiling, has a 2” thick black walnut mantle, and is trimmed out in a simple shaker style. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621280234617-LXATBAD0AGDAAJ4BAIH1/IMG_4877.jpg Malvern Fireplace Surround The black walnut I selected for this project had great grain and colors as you can see in this photo. http://www.greengatewoodworks.com/berwyn-builtin-bar daily 0.75 2021-05-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281834268-45HEUVT0YZWZ4Q7GRBX7/D4D5C0E2-4FE6-4BAD-B617-BF18C959E49D.JPG Berwyn Built-in Bar A client asked me to create a built-in bar for this alcove in their basement. They had an existing wine fridge they wanted to incorporate into the design as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281986894-24PMRBOGQHJKNDKENV5B/IMG_4933.jpg Berwyn Built-in Bar The black walnut countertop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281834553-OQDT0NTEYM6NOBBBJE4J/IMG_5120.jpg Berwyn Built-in Bar The finished project has inset flat panel doors, a black walnut countertop and shelf, and is painted in the Benjamin Moore color Hale Navy. http://www.greengatewoodworks.com/my-kids-builtins-1 daily 0.75 2021-05-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621282972912-9N2P381MOAB4K5DWUA7T/1217+girls+bulit-ins3.JPG My Kids' Built-ins My daughters share a room and needed some extra storage, shelving, etc, and we wanted to incorporate a window seat as well. Since it was for my own house, I didn’t take pictures except for these finished ones. The radiator cover on the lower right is held in place with magnets and easily removed when needed, and the bench seat lid opens up for trunk storage inside. I created lifted baseboards on this project to give it more of a “furniture” feel, and the entire project is up on 3/4” spacers to allow for installation of hardwood flooring in the future. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621282976345-41XFNYGG14QL81R0NBNO/1217+girls+built-ins2.JPG My Kids' Built-ins I installed color-changing LED lights along the top of the built-ins. They are controlled by a switch inside the center bookshelf, and there are additional outlets and USB charging ports at that location as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621282988414-6QDAV48RELAF7QOM5YTG/IMG_4024.GIF My Kids' Built-ins The LED light color can be changed with a phone app or the included remote. They can be set to sync their color changes to music or ambient noise in the room and my girls have incorporated this feature into their nightly dance parties. http://www.greengatewoodworks.com/newtown-square-builtins-1 daily 0.75 2021-05-17 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281143380-WWXT8ZQ6GZZVERZQEN2D/D936EDB7-94B4-42FB-B6BD-A19A5BBB6AEA.JPG Newtown Square Built-ins A client contacted me to create a set of built-ins flanking their existing fireplace. This was the space before I started. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281142925-5V7BRGBSCGZZTYPU17U1/7F7D98FD-81A9-4408-A5B1-643F8E3F8490.JPG Newtown Square Built-ins The finished product has lower cabinets for storage, upper bookshelves, TV mounted over the fireplace and a new mantle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281143507-E7MCQNS7NZS33DXR5KOJ/EC571B96-8269-47DA-8201-FAB6B6B86AF3.JPG Newtown Square Built-ins LED lights, hidden under each shelf and controlled by a switch on the inner side of the left bookshelves, add ambient light to the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1621281142934-1L7U9OMOJ7QEU4E5RVK3/AFB66A48-8229-447D-8052-BDF7145A7E5C.JPG Newtown Square Built-ins The clients’ kids took an interest in what I was doing while I was there, pulling up their chairs to watch me work. At the end of the job they gave me this very nice ‘thank you’ card. http://www.greengatewoodworks.com/berwyn-storage-room-door-1 daily 0.75 2021-11-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386278992-W8VUCRZ6CZB97YJ0CABU/82D15946-CDD4-404D-9DCF-255E287AF19A.JPG Berwyn Storage Room Door Chrissy McDonnell from Doyle & McDonnell, Inc came to me with a job to build a new door for a storage room on one of her client’s properties. The door in question was in bad shape, and the client wanted to match the style of their courtyard entry door, shown in the picture above. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386854434-Q9003J9JB7S4J9K6PVYS/2EBB1E89-915B-498E-9553-455F78106615.JPG Berwyn Storage Room Door After taking measurements from the courtyard door, I started making up the frame for the new storage room door. I used solid white oak for all the components since it will be an exterior door, and I beaded the frame to match the style of the courtyard door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386355615-8Q0Y5UI7BNYTC6KCJO40/IMG_5397.jpg Berwyn Storage Room Door After the beaded panels were installed, I added the upper grid and clamped the door up for final assembly. Plywood clamping jigs like the one seen here make life much easier when trying to clamp up a curved surface. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386355657-1PKIWWVSKS8X9YPE47EY/IMG_5475.jpg Berwyn Storage Room Door Prior to installation I painted the door using an oil-based primer and then several coats of exterior paint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386279928-NHHR821I0O0KSU2RAUH7/666E5E9D-23C3-466D-A124-FA7E2F61208E.JPG Berwyn Storage Room Door Here the door can be seen in it’s final home. I built new jambs, reused the latch and handle from the original door, and added dummy strap hinges to match the courtyard door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636386280274-3B1KZ6CJZZRFH0NL5CVU/12163736-9B39-4C04-B7F5-0D9A9AE8A1E5.JPG Berwyn Storage Room Door A wider shot showing the final product. http://www.greengatewoodworks.com/penn-valley-builtins-1 daily 0.75 2021-11-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636388288424-W6KTMM6YRSOE25CEHLY6/IMG_6453+2.jpg Penn Valley Built-ins A repeat client asked me to create a set of built-ins including a window seat in her living room as part of a large remodeling job she was undertaking. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636387640118-BSAMRKZK0YJH8M043SBO/IMG_6451+2.jpg Penn Valley Built-ins Here are the finished built-ins. They feature inset doors, lifted baseboards, and black walnut countertops and bench top. A large single drawer under the window seat provide additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636387640254-TN47HRQOYSF9X5FTSULN/IMG_6452+2.jpg Penn Valley Built-ins Behind each shelf are a row of LED tape lights that provide ambient lighting for the room and are controlled from a switch on the other side of the room. http://www.greengatewoodworks.com/warrington-office-builtins-1 daily 0.75 2021-11-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389505192-NOTVH6BRBWDFG348A3RH/IMG_6437.jpg Warrington Office Built-ins I was hired to make a set of office built-ins for a client, and they wanted to have a live-edge slab for the countertop. I found this large white oak slab which would fit the bill, but because it was so big I couldn’t fit it in my shop. My wife had to go up on the roof deck to take this picture to get it all in one shot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389358679-C6JLFJVHDNF3AWP7ID5Y/IMG_6497.jpg Warrington Office Built-ins Getting the large finished countertop into the house by myself took a little bit of creative thinking. I built these trucks from some materials I had laying around the shop which made the job a lot easier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389405429-O7HLDX5QRO4GN67I3NXA/IMG_6499.jpg Warrington Office Built-ins Getting the countertop in place was a bit of work as well. I set a block high on the side wall temporarily to give myself a chance to take a break and reposition myself for the final phase of lowering it place. Careful templating ahead of time makes it possible for me to fit large pieces like this in one shot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389360094-QKQEGAXV7U0NAEMI7XKW/IMG_6713.JPG Warrington Office Built-ins Painted in Benjamin Moore color Flint, the finished product features inset doors, adjustable shelves, and oil-rubbed bronze hardware. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636389360887-3EGRO59B9PG830BBJJH3/IMG_6756.jpg Warrington Office Built-ins A closer shot of the finished live-edge countertop. http://www.greengatewoodworks.com/warrington-mudroom-lockers-1 daily 0.75 2021-11-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636394845836-8FOREQAPGSDFC43HG4RP/IMG_6659.jpg Warrington Mudroom Lockers A repeat client hired me to create a set of lockers for their mudroom. The walls angled back in a way that made fitting 5 lockers in the space challenging, but not impossible. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636395095394-KTMVD13TZ765529P65UW/A35A2AAB-8D09-4A75-BAF2-0CE933EE1BD3.JPG Warrington Mudroom Lockers For the bench top I used reclaimed red oak barn wood. Finished with only a clear coat to preserve the character of the wood, it really turned out great. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636394845047-L7CNOZZ8DVYL2YDL1AQ0/B2B0CDB6-1498-4BEC-A3A3-C15FC34DB02A.JPG Warrington Mudroom Lockers The finished product. It has inset doors on the lockers, inset drawers below the bench, and an open spot above for baskets to hold smaller items. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636394844209-IRE95LCMHOCDFVGHUKT4/6A8D1566-5A30-4E17-978B-F561E4A08616.JPG Warrington Mudroom Lockers Another shot of the finished product from the kitchen. The raised trim details on the doors and drawer fronts was used to match the nearby kitchen cabinetry. http://www.greengatewoodworks.com/my-laundry-room-1 daily 0.75 2021-11-08 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396813401-708KG0L580CEGNSXIR8Q/IMG_5649.jpg My Laundry Room My own laundry room renovation was a project that was a few years in the making, and much more involved than my normal built-in projects. Our plans included installing a reclaimed brick floor, so the first step was to clear the room out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396822165-A4EPCAZ8QNDT82BXYEC9/IMG_5656.jpg My Laundry Room A layer of tar paper and wire mesh is installed prior to laying the wet bed for the bricks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396819417-EW5EJN1VUOLL91BYAIVM/IMG_5726.jpg My Laundry Room A base layer of mortar, the wet bed, is installed over the wire mesh, and the whole thing is pitched towards a drain in the neighboring mudroom. This is to drain water out quickly if the washing machine ever springs a leak. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396823048-0ICI9DO4HK7YT5B2OJEQ/IMG_5787.jpg My Laundry Room In addition to the slope of the floor, I added a waterproof barrier on top of the wet bed to aid with drainage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396826792-84J085OO2SKRQHN3DEWU/IMG_5857.jpg My Laundry Room Next up was installing the reclaimed bricks in a basketweave pattern. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396829552-FBZDGN8BL005MH0JEO5L/IMG_8405.jpg My Laundry Room After the bricks were installed, I sealed the bricks, then grouted everything. This protected the bricks from getting stained by the grout. Once the grout was cleaned up, I applied multiple additional layers of sealant to the entire floor. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396828329-2CJT3X26PVROBUAY305G/IMG_7903.jpg My Laundry Room After the floors were in, I added a wainscot ceiling. This portion of our home was original a porch, and we decided to maintain that character when we renovated, hence the brick floors and this ceiling. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396810654-MFAKSMY9D484BV5YEZS3/IMG_4234.jpg My Laundry Room With the brick floors and ceiling done for the time being, I moved the washer and dryer back into the room while I worked on the final cabinet design. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396807008-OBCXZWCTO3SY447T4WKP/B7425CF5-25DB-4FCE-B933-881A715B3A6D.JPG My Laundry Room This was the design I came up with for the room. Given the sloped ceiling and the uneven brick floors, the installation was going to be a challenge, but I enjoy projects like that. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396812141-YBYY80G0M7R0DOLWB4AF/IMG_4272.jpg My Laundry Room After installing the cases it was time to template for the countertop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396807775-N4DKICD8OJRF44S2AJWH/C3C15908-CC58-49FA-980B-F22CAF904B85.JPG My Laundry Room The finished project. The upper cabinets are angled to follow the slope of the ceiling, and the doors are angled as well to maintain a constant width between the top of the doors and the ceiling. This was done to leave room for the track which will be used for a future rolling ladder to allow easier access to pull out shelves in the upper cabinets. LED lights under the upper cabinets provide soft ambient lighting in the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396806231-RN33A29GM5GK7K0RLNTV/21B9DC0D-FDAA-4134-BDC7-874AB2A170F2.JPG My Laundry Room A large 30” farm sink provides ample room for soaking clothes, and next to the sink base is an open area for storing the laundry sorter. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1636396805553-7L3ZDXMRQ8XY963BHYH7/5FE590D4-1AFD-4B1C-AB33-0886F7FC4B1A.JPG My Laundry Room On the left side of the room is a false cabinet that conceals a laundry chute which originates upstairs in our master bathroom. Clothes pass through this false cabinet, down through the opening in the countertop, and then collect in a large pull-out drawer housed in the lower cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770943821715-SDX7BIPYFYOBQEXSPNKB/laundry+door+-+lightened.jpg My Laundry Room Between the laundry room and our mudroom, we installed this antique porch door as a pocket door. The original mail slot on the door added to the porch theme we were going for. http://www.greengatewoodworks.com/philadelphia-banquette-1 daily 0.75 2022-08-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661707666208-0R653KSMS0QQUZCZW83S/55E1CE2B-AF3F-4508-901E-01AE18BD0244.JPG Philadelphia Banquette For this job I was hired to create bench seating and create storage space for a growing family. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661707666354-S533Q802I7MR6G0VK27Z/C5756807-6D4C-4EF4-9FC7-435911AE0B65.JPG Philadelphia Banquette The finished banquette offers plenty of seating while also providing storage in two ways - drawers in the end of the side benches, and trunk storage in the rear bench. http://www.greengatewoodworks.com/haverford-french-door-conversion-1 daily 0.75 2022-08-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704519410-HPZ0QB0S7IVOUJYS9YFT/IMG_0262.jpeg Haverford French Door Conversion A repeat customer asked me to rebuild this pair of french doors for them. After some discussion they decided to change it to a single door instead of a pair of doors, but they wanted to maintain the look of the original doors as much as possible. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704525114-0B6UHPM1QGRZXCYMDWRL/IMG_0806.jpeg Haverford French Door Conversion My solution was to create a large single door that would have all the same trim details making it look like a pair of doors from outside. Built from solid white oak, the door was painted with several layers of oil-based primer and then several coats of exterior grade paint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704515476-MVTBO0OG5GT577K7L78G/67951049718__080B9BEB-1DFA-42CA-91B9-FBDB24808427.jpeg Haverford French Door Conversion The original doors had thin, single-pane glass which provided little to no insulation and were notoriously leaky in the winter. I upgraded the glass in the new door by using these custom made glass inserts that are filled with argon gas. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704533410-RY5PKZ2ZFA54NY1PL89H/IMG_0883.jpeg Haverford French Door Conversion After painting the door I delivered it for installation. A few years earlier I had bought a pair of door dollies, seen here, which make installation of large heavy doors a breeze. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704545572-LLDP85TSQGPAWCM817V8/IMG_0905.jpeg Haverford French Door Conversion The installed door provides a larger opening than the original pair of doors, making the space more usable for the client. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661704547320-TMDOENLW1KP7HKKORC4P/IMG_1109.jpeg Haverford French Door Conversion The location of the new knob and deadbolt are the only thing that gives away that this is now a single door. http://www.greengatewoodworks.com/merion-station-pair-of-built-ins-1 daily 0.75 2022-08-28 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701707050-ZDJBBKI8GVCR38P5CUZ1/IMG_8809.jpg Merion Station Pair of Built Ins I was hired to create a pair of built-ins in this client’s living room. One unit will go here with the other on the opposing wall across the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701607153-ZECWTIZ41Y933H8RFXJS/456645FB-1B87-4143-AAC0-056FDAC4768F.JPG Merion Station Pair of Built Ins These built-ins are the larger of the pair and features flat panel doors and drawers, and black walnut countertops. The kids of the house were staking claims to the window seat even before it was finished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701606471-N6PXX7OD9ADI1LO7Q90U/5BD56C38-3DAE-4448-9A7B-229CB974B026.JPG Merion Station Pair of Built Ins The built-ins also feature LED lights under the shelves which provide a soft light for the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701707018-6HPEQ1OJWT4GCORGUTKQ/IMG_8804.jpg Merion Station Pair of Built Ins This was the space on the opposite side of the room before I got started. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701606383-8R4ARKVJK34Q9SQTH41S/4D6DBB03-4DC6-4EDE-A5FC-CBE4E199DE52.JPG Merion Station Pair of Built Ins The finished built-ins feature the same flat panel doors and drawers as the other set, as well as a matching black walnut countertop. The open area of the countertop serves as a “launch pad” in the morning for the adults of the house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661701607015-MXJ4NE6HMKV38K5EUIIA/08FADFEC-BB0B-4487-9B25-772923A84BB5.JPG Merion Station Pair of Built Ins This unit has dimmable LED lights under the shelves as well. http://www.greengatewoodworks.com/malvern-builtins-1 daily 0.75 2023-10-03 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661706771179-ACXZ0P7BL7B4JCKDSTKJ/IMG_0065+2.jpeg Malvern Office Built-ins I was hired to create a set of built-ins for this client’s basement office. As you can see this was one of those times when I forgot to take a “before” picture and didn’t realize it until I had already gotten the lower cabinets installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661706837444-M4FF0P55H6HUVU9XS48M/IMG_0100+2.jpeg Malvern Office Built-ins After the lower cabinets were set, I fit and installed the countertop, and then installed the upper cases. After that I fit and hung the doors, installed the trim pieces, and painted everything to match the existing trim color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661706772969-BTYPVAYER2MTZ2H4B7H1/IMG_0184+2.jpeg Malvern Office Built-ins The finished product features inset flat-panel doors, a black walnut countertop, and a pull-out shelf inside the lower center cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661706772232-3VBBCBGU8HC90XSMTMOO/IMG_0179+2.jpeg Malvern Office Built-ins LED lights under each shelf provide additional lighting to the office. http://www.greengatewoodworks.com/emmet-brickowski-cabinet-1 daily 0.75 2022-08-29 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661733224340-038G4XNCAAV65KPZWD52/IMG_9558.jpeg Emmet Brickowski Cabinet Several times over the years I had made items to be auctioned off for my daughters’ nursery school fundraiser where the parents of each class put together a raffle basket based on a theme (“reading”, “wine”, “coffee lover” have been themes in the past for example). For my younger daughter’s final year at the school, I knew I needed to go big with my donation so I reached out to her teacher early in the school year to start thinking of ideas. I asked her what the theme would be this year and she threw out several options until she said “we could always do LEGO, the kids love that”. As a life-long fan of LEGO, I jumped on that one. I immediately envisioned a giant lego figure that was also a cabinet and quickly sketched the drawing above. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661733222137-D8RA3LD4BBG1H25VIDJY/IMG_7079.jpeg Emmet Brickowski Cabinet First and foremost I wanted to make sure that everything was proportional to a true LEGO figure, so I got out my digital calipers and started measuring every aspect of the figure. Then I used a spreadsheet to scale up the dimensions based on a few different final height options. Initially I had planned on just building a generic lego figure as seen here, but a few weeks into it I realized there was one figure that the kids would love more than anything else. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661732011241-DPYSHUP94OVP5SPP78VO/1F669C34-6A5D-4034-B76A-4768F7039326.JPG Emmet Brickowski Cabinet And that’s how I ended up building a giant Emmet Brickowski from The LEGO Movie. This Emmet is over 36 times larger than the actual figure. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661732011917-NBUAY57PCQ32BROESEF6/4A6B6ECE-A232-40AC-B862-E9C0F7CCA37C.JPG Emmet Brickowski Cabinet Emmet’s legs, torso, and head open up for storing your LEGOs inside, and, in order to be as accurate as possible, both the arms and hands rotate like an actual LEGO figure. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661732012747-CQCZPBLBI2R1FBRNGTQ5/48FB7DDB-690F-4206-B783-A28131D011A6.JPG Emmet Brickowski Cabinet All said and done, Emmet stands a little over 60” tall as shown here with me for scale. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1661733213026-BO204F1BS2JAQSMHF1OM/IMG_0045.jpeg Emmet Brickowski Cabinet Emmet ended up raising a good amount of money for the school and at the end of the day one of the kids from my daughter’s kindergarten class was the winner. As you can see here, he and his older brother were very excited about it. This was a super fun project and I’m already toying with the idea of making another giant LEGO man for my shop, based on the figure I made of myself when I built a scale model of my own house from LEGOs for my kids. http://www.greengatewoodworks.com/newtown-square-mudroom-builtin-and-wall-alcove daily 0.75 2023-01-15 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673812574647-BYBOTMJSOMI310C90P5M/6771E1BC-6B4C-4E0B-901B-87340F1A466B.JPG Newtown Square Mudroom Built-in and Wall Alcove A client asked me to create a new set of built-ins in their mudroom. The space was a little restricted due to the existing doorways, but there was a small recessed alcove on the opposing wall that created more opportunities for hanging storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673812575417-4CFJ5FSAOO1KSLBHSPE4/A882DDF8-3BE7-4D44-B338-3644BEA20015.JPG Newtown Square Mudroom Built-in and Wall Alcove Here is the finished built-in unit. It features a black walnut bench, open shoe cubbies underneath, closed storage above, and a stack of additional cubbies on the side that were designed around baskets the client had picked out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673812574369-M9BLHL21EDH4D1ALV7Q5/153AC213-0197-44D0-A208-5EE6C4E9B326.JPG Newtown Square Mudroom Built-in and Wall Alcove For hardware, the client found these bent railroad spike hooks from an online retailer, and they gave the built-ins a unique characteristic. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673812575534-ILPUEEEHK5JFCHKK9HAM/IMG_2733.JPG Newtown Square Mudroom Built-in and Wall Alcove The recessed alcove on the opposing wall has the same railroad spike hooks, and a black walnut shelf and custom-made wainscoting to match the built-ins. Photo credit: Melanie Lemke http://www.greengatewoodworks.com/secret-bookcase-door-1 daily 0.75 2023-01-15 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673816042245-D9YL682SVL38ZBE4SDND/IMG_1178.jpg Secret Bookcase Door A client I’ve done a few projects for contacted me to see if I’d be up for making a secret bookcase door. I love odd projects like this, so I jumped at the opportunity to do it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673816045074-ZKB4WLRCEH0L6J13FG57/IMG_1154.jpg Secret Bookcase Door After studying the hardware kit and its requirements, I built the bookcase and then did the finish trim work after I got it installed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673816035911-6824SJOYP0Z3LRDFW3ZW/4FB37930-054D-4DE5-9EBB-B597DFE7AEEB.JPG Secret Bookcase Door Here is the finished bookcase. The book on the shelf is part of the latch mechanism that releases and opens the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1673815958816-82ZF11GZMRPDGKNHNYYW/ezgif-3-e358dd5b12.gif Secret Bookcase Door Here is a gif of it in action. When opened it allows access to a walk -in closet. http://www.greengatewoodworks.com/media-builtins-1 daily 0.75 2023-01-18 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674081211283-KCCTEWSZCBWWYA7O24X3/IMG_7129+2.jpg Media Built-ins For this project the client was looking to create new storage space in their living room to replace their existing free-standing bookcases. This is the before picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674081133720-3LGB9T8N6QBUGXEJXNWL/4DC77694-70AE-4E7A-A831-8E6FD567BECC.JPG Media Built-ins The finished product is a series of lower cabinets and bookshelves in a classic Shaker style with black walnut countertops and bench top. New outlets were added inside the bookshelves for holiday decorations, and one outlet was added above the window seat for phone/laptop charging. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674081134859-KKA1HXBQ2YAIWDK99BCZ/8002E1A5-A453-4D14-A223-AE5FF7C1B400.JPG Media Built-ins The window seat creates a nice seating area with trunk storage below. The HVAC duct in the before photo has been relocated and extended to exit through the new baseboards. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674081133721-M3HZRKFROKN7UOBBNQGO/A35E45F6-1BC7-4651-B517-3794048E2FDE.JPG Media Built-ins Set on hidden Soss hinges, the bench top lid was cut from a single large blank, which allows the grain of the walnut to continue seamlessly across the entire length of the top. http://www.greengatewoodworks.com/chester-springs-dining-room-builtins-1 daily 0.75 2023-01-18 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674082434719-VHD2VO0BZNNPK7D45L9N/IMG_1966.jpeg Chester Springs Dining Room Built-ins For this project the client was looking to create more storage in their dining room, as well as a wine storage area above the new window they’d had installed prior to me beginning my work. As part of this project I also created a platform bed at their request for additional storage in their bedroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674082434296-55WKYVDEY2FOL0D3KFED/IMG_1972.jpeg Chester Springs Dining Room Built-ins These two support jacks came in handy when setting the wine rack cabinet. They’re an invaluable tool when you work alone like I do. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674082455708-HTEL3RQ7G3VC98HTTHHK/IMG_1993.jpeg Chester Springs Dining Room Built-ins With all the cases set and the doors/drawer installed, I painted the final finish coats. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674082457216-8IELK50WLLWO0F1HLDC7/IMG_2209.jpeg Chester Springs Dining Room Built-ins The finished product has flat panel overlay doors and drawers, and the entire piece frames their dining room window quite nicely. The lighting in this room wasn’t great for pictures so I had to lighten it a bit afterwards with editing software which is why this picture looks a bit grainy. http://www.greengatewoodworks.com/chester-springs-bed-platform-1 daily 0.75 2023-01-19 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674134070950-E00TG84QGBALFI74ZMV9/IMG_2009.jpg Chester Springs Bed Platform As part of this project, the client asked me to also create a storage platform for under their bed. For some reason I didn’t get any photos during the construction phase, the only ones I have start with this one taken during installation. The platform consists of 3 drawer bases with a center support panel, and I custom-made hardware to attach it to their existing headboard. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674133939183-5YQSKXBQHVJHT9SIMZUA/IMG_2211.jpeg Chester Springs Bed Platform The finished bed, reassembled. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1674133957895-A9OBRZWAQ1NUW3I2AIMQ/IMG_2212.jpeg Chester Springs Bed Platform There are 6 total drawers under the bed, 2 one each side adn 2 at the foot of the bed. The drawers are all made from solid maple with housed rabbet joints in the corners, reinforced with walnut dowels, and mounted on soft-close undermount drawer slides. http://www.greengatewoodworks.com/valley-forge-banquette daily 0.75 2023-10-03 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696369643540-9SD766YXO6QMEZJCF0AT/Graves4.jpg Valley Forge Banquette For this project the client was looking for a way to make this corner of their first floor more useful as a seating area and a mini-mudroom of sorts by their entry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696369642917-XMT0EYOCIY31G1K0VW65/Graves1.jpg Valley Forge Banquette The finished product features black walnut bench tops on the banquette, bookshelves behind and a coat rack area right next to the entry door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696369625799-TIQ5XFGVR9ZOQO2FS5UP/Graves2.jpg Valley Forge Banquette The benchtops open up for additional storage inside the banquette, and under-shelf lighting in the bookshelves provides a nice ambient light for the area. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696369642937-DMFAIE0WH8AXOCH1N49N/Graves3.jpg Valley Forge Banquette A close up of the hanging area. A double row of hooks is mounted on black walnut boards to match the benchtops, the shelf above provide additional storage for smaller items, and it’s all mounted on custom wide wainscot paneling. http://www.greengatewoodworks.com/malvern-builtins-3 daily 0.75 2023-10-03 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371300361-2KYABVDF83IM4WJFVUBQ/Clark4.jpg Malvern Built-ins Often times when creating built-ins, I’ll fill an entire wall, but in this case the client wanted to do only a section of their living room wall to act as a focal point, while providing a nice spot for their TV and additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371324877-X7W6GBD293DBVFB5H1C2/clark1.jpg Malvern Built-ins The finished project has inset flat-panel beveled shaker doors, beaded face frames, and a black walnut countertop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371324899-VEOWML6AG92ZA3IY1L2V/clark2.jpg Malvern Built-ins Under-shelf lighting add a soft ambient glow in the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371300340-ROSB0FUNEBDM5WQBUXUY/Clark3.jpg Malvern Built-ins Beaded face frames as a subtle detail in a project that give it a classic look. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696371301007-PRQT1PVINTVO7FZ54PFJ/Clark5.jpg Malvern Built-ins The client was kind enough to send us a photo of the built-ins after they had gotten them decorated, and it really turned out great. http://www.greengatewoodworks.com/st-matthews-school-sign-1 daily 0.75 2023-10-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696465251356-7ZFQQGJLMENBHJHBFXSN/St+Matts1.jpg St Matthew's School Sign When my kids went through the St. Matthew’s School a few years ago, it was a tradition of sorts for families to take their “first day” photos by a small sign on the walkway to the school. The school contacted me about making a new one for the school’s 20th anniversary, so I created this design based on the characters in the school’s logo. The “first day” panel is held in place with magnets and can be exchanged with one that reads “last day.” The numbers use the same magnet system and can be updated for each school year. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696465263384-BKBQT1ILG6CR04HHVRJ9/St+Matts2.jpg St Matthew's School Sign I included enough extra numbers, so the school will be set for the next 100 years or so. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696465263461-MCJMZPRMQ077RB84M4K4/St+Matts3.jpg St Matthew's School Sign After dropping it off, the director of the school, Sandy Elkins, was kind enough to model for us. http://www.greengatewoodworks.com/malvern-staircase-slide-1 daily 0.75 2023-10-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696466701512-J5QZVZK9G2ITFR3V45V9/IMG_3628.jpg Malvern Staircase Slide Every now and then a client brings me a super fun/weird project outside my typical cabinetry jobs, and this was one of the best. This client had put up homemade slides for her kids in the past but wanted something a bit safer and with a smoother transition at the bottom. The first step for me was to take detailed measurements of the existing staircase, then draw the entire thing out to scale and start figuring out the sizes of each section. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696466807952-FP3JQMWD1SE4UNTG3UZP/IMG_3684.jpg Malvern Staircase Slide This is the bottom “transition” section before I applied the top layers of plywood. Each section of the slide has multiple ribs inside for structural stability. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696466051107-KZB340NYQBGCQ58IIHCZ/slide2.jpg Malvern Staircase Slide A before picture of the staircase. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1696466051070-OJDLIBUMMM9B9JUJKQNQ/slide1.jpg Malvern Staircase Slide The finished slide consists of five different sections that interlock with each other. They are secured to the stair risers using threaded inserts, so it can be quickly installed or disassembled for storage in just a few minutes. http://www.greengatewoodworks.com/shop-door-rebuild-1 daily 0.75 2024-11-03 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641870161-H12ZW9LLXKMNHFQC1RYL/IMG_7111%2B2.jpg Shop Door Rebuild I’ve been wanting to build some new doors for my shop for a while to replace the temporary plywood ones shown here, but the material costs were a bit prohibitive so I started searching around for alternatives. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641460037-WBVEPVVSRLFL5JGA9D93/IMG_8024+2.jpg Shop Door Rebuild I found this pair of old barn doors that were the perfect width for what I needed, the only problem was they were about a foot too tall so I’d have to cut them down and rebuild the bottom portion of each door. The next series of photos will show the process in depth. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641382407-SGSMLDUQMME5QKF0JYCL/IMG_8123.jpg Shop Door Rebuild First step is cutting the door to its final height using the track saw. I use the track saw instead of trying to push the door across my table saw because it’s more accurate and safer to do it this way. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641386389-W72L5VMVZX00HSQA1DHA/IMG_8124.jpg Shop Door Rebuild After the bottom portion of the door is removed I needed to remove the pieces of the stiles (the vertical elements of the door) and the bits of the center panels so I could isolate the bottom rail (horizontal elements of the door). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641396632-CGJ7Y21HQUA4SVJGYGYK/IMG_8128.jpg Shop Door Rebuild Here you can see the rail after I removed the extraneous pieces. After this I cut off the original extended tenons from the rail (those “ears” that are sticking out on each side). Those extended tenons help increase the structural rigidity of the door, but I can’t reuse them in this case without completely taking the door apart which I didn’t want to do, so I’ll reinforce that area of the door in a later step. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730642420356-N3UTWVUO2DTUD798GYRJ/IMG_8129.jpg Shop Door Rebuild Next step is to measure the height of the bottom rail so I know where to make my next cuts on the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641404486-USITC84Z22YZBI9WCK12/IMG_8132.jpg Shop Door Rebuild Using my track saw again, I line up the track with the bottom rail height measurement and then cut out the center of the door, making sure not to cut the outer stiles of the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641414146-6EHY5QTLUOHNMELXRVQI/IMG_8136.jpg Shop Door Rebuild After making the cut, I remove the cut off pieces of panel and inner stiles. This space is where the bottom rail will go. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641421023-A5F8YLE1QT3D05KMYEA4/IMG_8137+2.jpg Shop Door Rebuild This door was originally built with a rail-and-stile technique where the rails and stiles have interlocking profiles to nestle together snugly. In this case, the original builder used a rounder profile, and luckily I had the matching router bit sets already in my tool collection. I used my festool router to cut the rail profile into the ends of the inner stiles. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641420206-KVX6M5UHNND6AZY6XIPU/IMG_8139+2.jpg Shop Door Rebuild Here you can see the rail profile, which is just the inverse of the stile profile cut. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641428974-S7X9UB71S7ASTFIDQMLF/IMG_8141+2.jpg Shop Door Rebuild The original panels were tapered at the bottom in order to slide into the bottom rail, but since I cut them off I removed that tapered bit and had to redo it. I started out with a straight bit in my laminate trimmer to remove the bulk material. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641435030-3MINSUVPDTSYXKCJ19KM/IMG_8143+2.jpg Shop Door Rebuild With the bulk material removed, I used my chisels to taper the ends so they’d slide nicely into the bottom rail. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641435610-X396D50SZB3QCZYSA90Q/IMG_8150+2.jpg Shop Door Rebuild The bottom rail is now ready for a dry fit to test everything out and check for any last minute adjustments that may be needed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641373401-29MJ424G5BF4FSUORGYI/IMG_8107.jpg Shop Door Rebuild I mentioned earlier how I would need to reinforce the door structure since I had removed the original extended tenons from the bottom rail. I added four of these long floating tenons (or “dominoes”) on each side of the door using my festool domino joiner. These dominoes are made from sapele, a tropical wood that’s good for use outdoors. I could probably get away with the standard beech dominoes, but I had these sapele ones on hand and it never hurts to overbuild things. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641376521-RNXEFV0388S8CAAH5PI7/IMG_8114.jpg Shop Door Rebuild Each side of the door gets four of these dominoes which are driven in from the outside, glued in place, then clamped overnight. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641442567-VNWIJH144RC69L0Z4ZBN/IMG_8151.jpg Shop Door Rebuild This is the rebuilt door reassembled and ready for the next stages. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641380226-3QTC7X30OVHTVGPM94CT/IMG_8117.jpg Shop Door Rebuild Here you can see the difference in height. The original doors were around 108” tall and ended up around 94” tall when I was done. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641442843-6PPVW8HRFJ5HTUM1TRUV/IMG_8162.jpg Shop Door Rebuild Once I was done with one door, I repeated the process with the second door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641450837-OXDXMY6956FWK0N85D2Y/IMG_8813.jpg Shop Door Rebuild The finishing process involved some epoxy work to fill a few voids, then a lot of sanding to remove the old paint as much as possible. Then I did 3-4 coats of oil-based primer, and finished the doors off with an exterior grade topcoat. Because these doors were so large, I couldn’t attach the full jambs ahead of time and install them as a pre-hung unit. Instead, I attached a jamb to each door, then moved them into place with my dollies. If you’re working with large heavy doors, these dollies from Door Stud are invaluable, especially if you work alone like me. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641451450-DOTWD17X095P2BWDNUFC/IMG_8896.jpg Shop Door Rebuild After I got each door into position, I secured the jambs to the framing, installed the upper jamb, and then put on the hardware. After that I replaced some missing and broken glass in these doors with antique glass that was salvaged from a friend’s 1860’s era home near my shop. I don’t know the age of these doors, but the original glass was fairly wavy and the antique glass I used was a great match. Last thing to do was install the exterior trim and capping. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1730641456668-IKK7QEQIH52JMKE8SB4Y/IMG_9166+2.jpg Shop Door Rebuild The final doors make a great addition to the shop. Next up will be installing a dark green vertical metal siding and then Chester County field stone to the cinder block portions of the walls to match the stone on our home. The color of these doors, Sherwin William’s “Kaffee” (SW6104), was chosen to complement that future field stone. . The original temporary doors I built had a dog door for Sydney but after all the work I did on these doors I couldn’t bring myself to cut a hole in them, so I moved her dog door to the back of the shop. http://www.greengatewoodworks.com/lafayette-hill-fireplace-builtins-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737646768287-D64BIU2HRSZSZXW0RS1D/27A77288-35CC-47EB-AE53-762AD20966BF.JPG Lafayette Hill Fireplace Built-ins This massive brick fireplace and hearth dominated the room, and the clients wanted to gain more storage while reducing the overall feel of the fireplace by installing built-ins. To cut out and remove the bricks would have been costly and very messy, so I decided to work around them instead. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737646767459-MNVNO82IJGPYN2RD37K5/2CB32112-E67B-49F5-A6E7-A581857CD54A.JPG Lafayette Hill Fireplace Built-ins The finished built-ins were designed to wrap around and conceal the bricks underneath and behind, while still providing plenty of storage space. The cabinet on the right is just a standard cabinet, while the one of the left is a bit different. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737646769013-AUPQKD57MI2GR2T3JOJL/83F13923-5647-42C8-B5D7-F72BE901A898.JPG Lafayette Hill Fireplace Built-ins The left cabinet houses a large firewood drawer the client requested, and I faced it with two false doors to give a balanced appearance to the overall project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737647903361-I16YRXWAER08N30TYD9P/8E33C201-3D23-4A24-B17B-DD9584A157B7-1+copy.jpg Lafayette Hill Fireplace Built-ins The clients were also kind enough to share this photo of the finished project after they had decorated. http://www.greengatewoodworks.com/bala-cynwyd-sideboard-and-shelves-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737649387433-XIE5N1V1BRIMTLMY6GK9/IMG_4167+2.JPG Bala Cynwyd Sideboard and Shelves Finding the right slab for a project is sometimes a Goldilocks situation. For this project - a sideboard for the dining area of a kitchen - I needed about 7’ of a live-edge white-oak slab. While searching for the right piece, I found some that had no character to the edge, while others had far too drastic of a curve to work. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737649590131-VGHMSIIRQFZ1KYEIUIKZ/IMG_4195+3.jpg Bala Cynwyd Sideboard and Shelves This one was just right: a gentle curve with some interesting features, great colors, and enough material left over to make matching shelves for the alcove. Finished with only a clear-coat and no staining, the natural colors of the wood really shine through. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737649589538-DMF0L16XZPXVT311DGK3/IMG_4193+3.jpg Bala Cynwyd Sideboard and Shelves https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737649590662-KG7RY0TINC3NG01LS7PM/IMG_5210+crop.jpg Bala Cynwyd Sideboard and Shelves With a starting length of 13’, this slab was a bit of a challenge to handle. I had to make up some new dollies just to move it around, and it required using my truck’s winch to unload it safely by myself. All worth it in the end though, as the project turned out beautifully. http://www.greengatewoodworks.com/bryn-mawr-living-room-builtins-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737650463001-LSAKZSHK728WQOYW0299/Screenshot+2023-10-01+at+9.26.35+AM+2.JPG Bryn Mawr Living Room Built-ins One of the benefits of having custom work done is that you can take the various components of a project into account ahead of time to figure out the proportions needed to make the whole design come together perfectly. In this case, the central section of the project was sized to accommodate the dimensions and requirements of the new gas fireplace, as well as the artwork above (which is actually a TV). I then designed and fabricated the built-ins and mantle to match those proportions and have the most efficient use of space for maximum storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737650572662-GZDSYN67NSWDB59BSCIC/IMG_8785+2.jpg Bryn Mawr Living Room Built-ins Featuring inset flat-panel beveled shaker doors, beaded face frames, and chamfered columns, these built-ins and fireplace fill a once empty wall and really changed the feel of this room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737650571266-2OXK1UL97SEVEJ2DK4OB/IMG_3947+2.jpg Bryn Mawr Living Room Built-ins This is the “before” picture - all fireplace installation including framing, drywall, electrical, and the marble surround was handled by BTR Home Improvement and Construction (www.btrcustombuilders.com). https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737650661212-LROV2PLH9MZWJZ96NTHK/IMG_7763.jpg Bryn Mawr Living Room Built-ins A while later I was back at that client’s home to discuss another project and got this shot of the fully decorated built-ins. http://www.greengatewoodworks.com/paoli-bookshelves-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737652602596-PUBCIXDURI0B971GJZGG/IMG_5295.jpg Paoli Bookshelves The client on this project contacted me because they were looking to solve a couple of issues they felt their living room had. It’s a somewhat narrow room with fairly low ceilings, and they wanted something that would draw the eye up to make the ceilings feel a bit higher without extending out into the room anymore than necessary. Their home was also lacking bookshelves, and they thought a floor-to-ceiling set of shelves would do the trick. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737652599647-CH59UV8Q04XFEOTDE94O/IMG_5294.jpg Paoli Bookshelves With the addition of the under-shelf lighting, these bookshelves create a nice focal point in the space without overwhelming it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737652598490-37QJ7W4YD21ETHGJSA1N/IMG_5115.jpg Paoli Bookshelves Before picture (sort of); I didn’t remember to take a picture until I had already gotten started. http://www.greengatewoodworks.com/gladwyne-window-grids-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737653472002-NFY8KTFU9AFN66M8O0PV/IMG_4493+2.jpg Gladwyne Window Grids Sometimes little things can make a big difference. A long-time client of mine owns this circa 1830s home in Gladwyne, and she strives to maintain the character of the home. The original windows had been replaced by a previous owner with casement windows, which just didn’t look right. In lieu of replacing the windows again, she asked me to make grilles to give the appearance of traditional divided-lite, double-hung windows. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737653470146-26EXLM6RT5PSM7TNLXSK/IMG_4494+3.jpg Gladwyne Window Grids Although it was a challenging project that involved overlapping multiple thin layers of wood that are prone to breaking during the fabrication process, the finished product really makes an incredible difference in the home’s facade. . https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737653472004-C59FSKKV8ZL47O0XPNZ4/IMG_4528+3.jpg Gladwyne Window Grids I forgot to take a “before” picture, so I grabbed this screenshot from Google Street View where you can see how the windows looked to start. The interior of the home is as charming as the outside, and I’ve had the good fortune to work with this client on multiple projects, like this spalted maple mantle, floating shelves, built-in linen closet, and small bar cabinet. http://www.greengatewoodworks.com/penn-valley-office-builtins-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737667805113-6O10W99Q5CPB7GMS562R/IMG_9836.JPG Penn Valley Office Built-ins Green is my favorite color, and I like working in older houses, so I especially enjoyed creating these office built-ins for this Penn Valley home, built circa 1800. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668054010-MK26HNSAJGZH7YLIV5YU/IMG_9837.JPG Penn Valley Office Built-ins Matching the original wall color, Sherwin Williams “Shade Grown” (SW6188), the built-ins feature beaded face frames, inset flat-panel doors and drawers, and the under-shelf lighting and wall sconces add to the cozy feel of the room. Pull-out shelves inside the center unit will give easy access to a concealed printer, and one of the drawers has two in-drawer outlets for charging iPads, phones, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668289997-JLEXW7F6Q85IXTBW7USH/IMG_6671.jpg Penn Valley Office Built-ins After I had finished, the clients sent me this photo of the decorated built-ins. Overall this was a fun project, and what pleased me most was what the client said to me when the job was completed: “It looks like it’s always been here.” http://www.greengatewoodworks.com/media-mudroom-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668985478-01SXEMYO8GWH47UC756B/IMG_9839.JPG Media Mudroom Planning for the future is important when designing a project. A previous client had moved and contacted me to create a mudroom area in their new home. They wanted to use a space that was an extension of the kitchen for the mudroom; however, their refrigerator is currently housed there. As part of a future renovation, the fridge will move elsewhere, freeing up space for a larger mudroom. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668985699-NEPMNDWIVCHE02EBP6O9/IMG_9840.JPG Media Mudroom In this current phase of the project, I removed the original cabinetry, swapped the radiator out for a shorter, lowboy unit, and then built these lockers with a black walnut benchtop, stopping just short of the fridge. When creating the benchtop for this project, I fabricated one large enough for the entire future space and cut it to length to accommodate the fridge. The remaining section of the benchtop slab will live in my shop until it’s time for Phase II, when I’ll join the two sections back together again. By taking that approach, I’ll be able to line all the wood grain up nicely, resulting in a more seamless finished product. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668986394-9ZDH9S5FUYLLRABU83YO/IMG_9841.JPG Media Mudroom These multi-tiered hooks swivel open and provide a lot of options for hanging storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737668986660-VIXYR3WCREDUQGOT87O9/IMG_9842.JPG Media Mudroom The original cabinetry and radiator cover that I removed. http://www.greengatewoodworks.com/malvern-multiple-builtins-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737669835407-KE9JNVH7CMGN8C53Q3IL/IMG_9843.JPG Malvern Multiple Built-ins A repeat client contacted me after moving into a new house and was in need of storage solutions throughout her home. She has an affinity for built-ins, as her last several houses have had them, so I designed and built several different projects for her. The first one featured here is additional kitchen storage in what was once an empty alcove. The bottom features two large file drawers on the left and a storage area on right side of the cabinet. It’s topped by a black walnut countertop, which looks nice paired with the custom wainscot backsplash. The cabinet on top features overlay, divided-lite glass doors to match existing the kitchen cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737669835783-CKSOO94OD9DIRKFJI19V/IMG_9844.JPG Malvern Multiple Built-ins The file drawers have metal bars set into the drawer box to accommodate standard size hanging file folders. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737669836372-S7B54EAC2A38C04GEJ2D/IMG_9845.JPG Malvern Multiple Built-ins This family room wall , originally blank, was completely transformed with a pair of built-ins tied together with a new mantel and custom wainscoting which matches the kitchen built-in. New sconces I installed above the mantle will highlight some of the client’s artwork. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670141316-IO9OCBQW14H454M7PE6H/IMG_7351.jpg Malvern Multiple Built-ins Across from the large living room built-ins is this cabinet set into a nook to house their TV. The cabinets are a full 24” deep for plenty of storage, and a false back in the central section keeps the TV close to the front for easy viewing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670148111-B1ZA12PTJXC48QRMX5NN/IMG_7355+2.jpg Malvern Multiple Built-ins In a room adjacent to the living room is this set of bookshelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670142814-E0769SN0PUL18VO0YA43/IMG_7216+2.jpg Malvern Multiple Built-ins The final set of bookshelves is set in an upstairs bedroom. http://www.greengatewoodworks.com/malvern-mudroom-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670947642-210J9LC3JAEJE311DVUR/IMG_9851.JPG Malvern Mudroom This mudroom created a massive amount of storage for the client. The open cubbies below the black walnut benchtop provide ample room for shoes, etc., while the folding triple hooks mounted above on a matching black walnut board provide lots of options for hanging storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670947949-1RDW3RDUYMP6Q7L2VPIO/IMG_9852.JPG Malvern Mudroom The overhead enclosed cabinets and open cubbies on the right, which are sized to fit baskets the client picked out, create a great spot for storing smaller items and seasonal things (gloves, hats, etc.) https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670948623-X39VVZY2EVXFCV3MXJY0/IMG_9853.JPG Malvern Mudroom The tall cabinet on the far left boasts two pull out shelves in the bottom section and even more folding hooks in the upper portion. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670949344-VAZ3XSGFOFE7GOFP4OLH/IMG_9854.JPG Malvern Mudroom The custom wainscoting in the main hanging area adds a nice subtle detail to stand out from the crowd. This project was painted using Fine Paints of Europe Eco Satin in Farrow & Ball’s Blue Grey #91. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670944180-8S144NR00XEWKWCX89MF/IMG_9846.JPG Malvern Mudroom This cabinet sits directly across from the lockers and provides even more storage space in an existing alcove. On top of the black walnut countertop sits a stand-alone mail organizer, also made from black walnut. The difference in color is due to how the boards are treated at the mill, which I’ll explain in the final picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670944599-4UQI5B94XLKRSVJNLCTL/IMG_9847.JPG Malvern Mudroom Inside the cabinet, there’s a drawer that houses a container for dog food with additional storage behind it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670945098-LN3VF0I68X0CDWU3JCVY/IMG_9848+2.JPG Malvern Mudroom The small door behind the dog food container allows access to the interior of the drawer where small items can be stored. Cut from the original drawer top, the door grain matches its surroundings seamlessly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737670945994-1ANQS0X48O0XAO2Y6BD5/IMG_9849+2.JPG Malvern Mudroom The difference in the color of the countertop and the mail organizer is because the countertop walnut is steamed, and the mail holder walnut is not. When walnut is steamed, it results in a more uniform color between the typically darker heartwood and much lighter sapwood. While both steamed and unsteamed walnut look great, steamed walnut is nice to use when creating a countertop from multiple boards because it’s more consistent in color. Walnut that hasn’t been steamed has bolder, more dramatic colors, and I had a couple pieces I was saving because they were so beautiful, so I decided to use them to fabricate the mail organizer. The boards weren’t quite wide enough for what I needed, so I resawed them and bookmatched the pieces. This aligns and mirrors the grain, as shown above. http://www.greengatewoodworks.com/merion-station-builtins-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737672816815-L181MX2G81MYJ3PJ42UO/IMG_7563.jpg Merion Station Built-ins For this project, the client wanted to convert an existing alcove into a set of built-ins that would conceal their TV when not in use. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737672822648-WKNJM117CWSBMAO3MROD/IMG_7715.jpg Merion Station Built-ins The finished project features inset flat-panel doors and a black walnut countertop. Set into the countertop and the upper cubbies are a pair of tracks the doors ride in. When opened, they stack up over the outer open shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737672816589-78IN7P9H79LYEAHXLYGN/IMG_7714.jpg Merion Station Built-ins When closed, the doors conceal the TV and give the project a unique look. http://www.greengatewoodworks.com/merion-station-library-builtins-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737673699227-8OG0RQLM1XF8KU2JR7HA/IMG_9856.JPG Merion Station Library Built-ins “Help us create our library!” was the request from this client, who was looking to redo their third floor office space to give it a cozy, library feel. The built-ins that replaced the original filing cabinets (before pic at end) have raised-panel, inset doors to match other doors in the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737673699421-NJO8MZ8YOZ6XLR2TL4M0/IMG_9857.JPG Merion Station Library Built-ins The large drawer under the window seat is the perfect place to stash a blanket for curling up with a good book, and under-shelf lighting adds to the cozy vibes. I certainly got a workout hustling up and down the stairs all day, but it was worth it in the end. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770854407109-W3BCABWJ4Q9TFLRKD7S1/Screenshot+2026-02-11+at+3.05.30%E2%80%AFPM.png Merion Station Library Built-ins After my work was completed, the client had wallpaper installed along the back of the bookshelves and was kind enough to send me this finish picture. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737673700064-LZVS0IVBMVHAS7WTAGUA/IMG_9858.JPG Merion Station Library Built-ins “Before” pic http://www.greengatewoodworks.com/chester-springs-window-seat-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675131175-H2P8Z2A9FCB8AMCO1SY2/IMG_8622.jpg Chester Springs Window Seat This client needed additional storage in their kitchen, and wanted to utilize the dead space under their existing window seat. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675230704-MKETCR3509VDFMXG0QQU/IMG_8717+2.jpg Chester Springs Window Seat I removed the existing drywall and studs, leaving a temporary prop in place to keep the window seat top from sagging. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675131537-AD0Q4QMSKUQIU5UBVA09/IMG_8720.jpg Chester Springs Window Seat I built and finished this drawer base in my shop, then slid it into place under the window seat top and secured it to the framing inside. Now, the window seat remains, but provides plenty of storage in the large drawers below. http://www.greengatewoodworks.com/lego-display-bookcase-1 daily 0.75 2025-01-23 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675963546-0YHDZX8BIKFNME2KCCVP/IMG_9859.JPG LEGO Display Bookcase This client was looking for something where her kids could display their built LEGOs. If you know me, green and LEGOs are two of my favorites, so this was a fun project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737675963893-4S5NH2WBRKO6DT6F1AS1/IMG_9860.JPG LEGO Display Bookcase I had barely installed it before the kids started loading it up with their LEGO creations. http://www.greengatewoodworks.com/spalted-maple-desk-1 daily 0.75 2025-01-25 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734595048-I9XAFL0P8C401WN49XSZ/IMG_7220+3.jpg Spalted Maple Desk This project came to me from a repeat client who loves spalted maple. She asked me to keep an eye out for a large piece that we could turn into a desktop, and I came across this slab with absolutely beautiful coloring at Groff & Groff Lumber https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734595015-IEAQCNU8FTEAVRLUSVGO/IMG_8826+2.jpg Spalted Maple Desk In order to find the best layout, I made up a template from plywood strips showing the finished size of the desk. I moved it around until I found the position that had a nice balance of color and worked well with the thickness of the slab which was variable on the bottom side. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734607281-PNZUJ97W15P2EQSMDV3Z/IMG_8858.jpg Spalted Maple Desk Once I had cut the slab to size, there were a few areas that needed reinforcing with epoxy, specifically the back edge of the desk where the slab was a little thin. I attached temporary plywood pieces to the areas that needed to be reinforced, then did several epoxy pours until low areas were filled in fully. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734608127-IG992UTW6BUAB432YA3V/IMG_8997a.jpg Spalted Maple Desk After the epoxy had cured for a few days, I sanded the entire slab down, finished it with a wiping varnish to match other spalted pieces in this client’s home, and then I attached it to the motorized desk base. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734621369-M59NTUTQH2PVM1C5QA3T/IMG_9143.jpg Spalted Maple Desk The finished product delivered and installed at the client’s home. This is a standing desk base from Uplift and raises and lowers at the touch of a button to transition from sitting height to a standing desk. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737734621938-LNXTSP4LMMBZWOHT2WY0/IMG_9148.jpg Spalted Maple Desk Another shot of the finished project. http://www.greengatewoodworks.com/emmet-build-pics daily 0.75 2025-01-25 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838297133-4S0ODW1B6AC6ZZBW8M4K/IMG_7079.jpeg Emmet Build Pics This is the more in-depth record of the build of Emmett, mostly written for my own records, but I figured some people might be interested in reading through it. These aren’t all the pictures, nor are they in the exact order I did things. I tend to jump around working on various aspects of a project like this where there are many different issues to be sorted out based on whatever solutions I’ve come up with at that moment. That being said, I’ve put the pictures in what I consider to be a somewhat logical order. After coming up with the initial idea, I took detailed measurements of all aspects of a standard lego figure with my digital calipers, then set up a spreadsheet that would scale them up according to the final size I wanted the piece to be. I ran several different options at the same time until I found the numbers that I felt made the most sense, primarily based on the depth of the torso cabinet section as that was the main storage area, which was based on some plastic bins we had found which went with the figure for storing lego bricks. This was one of the first projects I did in my new shop after renovations. The actual construction on this (not the time I spent figuring out dimensions, planning, etc) started on or about Feb 26th, 2022 and ended on April 25th, most of the work being done in my spare time between jobs, on weekends, and in the evening. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838301015-2IR9RMQYI9ZUFJOKO0SD/IMG_8929.jpeg Emmet Build Pics The first section I built was the torso cabinet because it seemed the easiest place to start since it’s fairly straight forward. Typically I set fixed shelves in my cabinets into dadoes cut into the sides and back of the case, but with this one the angles made cutting those dadoes difficult, or at least enough of a concern that I’d spend too much time fixing mistakes, so I cut the shelves to size and glued and tacked them from the outside. Since they won’t be holding much weight, this was an acceptable compromise from my normal techniques. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838301622-98NTS0LDJEPAOGHLP5DQ/IMG_8933.jpeg Emmet Build Pics For the leg cabinet, the bulk of it is also a straight forward cabinet case, just with the outer side run long. I found the center point of the radius for the upper section of the leg and marked the curve so it sat above the flat top of the leg cabinet, this will get trimmed off later to that curved line. The upper “waist” portion of the legs will be a torsion box added later, and the outer face of it will follow that same curve and sit directly on top of the leg cases, giving the legs the appearance they rotate even though they are fixed in place. For the door front, I used a single piece of 3/4” cabinet plywood, built a small box from primed pine for the toe, then cut two plywood arcs for the upper curved portion of the leg. In between those two arcs, I filled in the space with primed pine strips cut with angles on the long edges so that they would follow that arc approximately. Those primed pine pieces are later sanded down to match the curve of the plywood arc pieces, although that won’t show up in the pictures for a while. I also added thin strips of primed pine to cover up any exposed plywood edges, they can be seen here (the white strip between the door and the main cabinet case), and can be see in pictures moving forward on the torso cabinet. I added them to the torso cabinet face, the front of the shelves, and to the edges of the torso doors as seen in later photos. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838279472-GYV61SZU09SLO57XACUC/IMG_3699.jpeg Emmet Build Pics I don’t have any pictures of it, but the center portion of the legs (between the leg cases and the torso cabinet) is just a plywood torsion box. At this point I hadn’t cut off the upper portion of the leg cases, that’s taken care of later, for now I was just testing the overall fit to see how things looked, but because of that the legs are spaced farther apart than they will be at the end. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838306352-0I8CFHVZJEZ1NB0TF8SM/IMG_9043.jpeg Emmet Build Pics For the arms, I had to create a couple tubes built up out of long primed pine rips with angled sides. This is for the lower forearm portion of the figure as they are straight tubes, and this was enough to do both forearms. I used biscuits on each piece to join them up and to keep the pieces from slipping during the glue up process. Once I got them loosely assembled I used tie down straps to tighten up the joints and then left it overnight while the glue dried. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838306352-ILS4785UNMZ8MWNL4W0F/IMG_9045.jpeg Emmet Build Pics This is looking down at that forearm tube from the top to show the angled pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838325697-TBO3E4MN39EX8O7AVK1H/IMG_9087.jpeg Emmet Build Pics The upper arms were more difficult because they were tapered tubes, figuring that out took a bit more math, shown in later photos of my notes. I used this tapering sled from another project to make the pieces. First step if clamping a piece of primed pine in place, then running it through the angle saw blade. In this photo, i’ve already done done one side of the rips. As I recall I had to do one rip on each piece, then adjust the sled to do the other rip so it was at the proper angle. If i’d used the same sled and just rotated the piece, I’d have ended up with a straight piece at the end instead of a tapered one. Don’t seem to have any pictures of the first pass, but that was probably done just against the fence on a table saw with no sled, I think the sled was only used to do this second pass which created the taper. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838326661-X9J8UBD6URIQCE055UGP/IMG_9088.jpeg Emmet Build Pics This is the final tapered piece, it’s upside down (you’re seeing the inside face of it) because my saw blade leans to the right. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838329520-JB46QAY8GD3II6TB45PR/IMG_9089.jpeg Emmet Build Pics This is the narrow end, the bottom of the upper portion of the arm, essentially at the elbow. As I recall, this dimension was the same as the forearm tube pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838330565-BUKRLZHJI206DWR5Y092/IMG_9090.jpeg Emmet Build Pics This is the wide end, the top of the arm. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838334376-7E1U8V75GMBKY03SS5L1/IMG_9096.jpeg Emmet Build Pics i assembled the upper arms the same way I did the forearms, with biscuits, glue, and tie down straps. After the glue had cured overnight, I marked out the angle needed to create the elbow joint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838335004-BAWVKN8D00EE2Y6BGGR9/IMG_9098.jpeg Emmet Build Pics In order to get a straight cut on the tapered tube, I made up a tapered sled for it to right on while going through the band saw. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838339376-4QQ2OJXLJQ0YCN7VZMF3/IMG_9100.jpeg Emmet Build Pics Since the cut was also on an angle, I just took my time and free-handed it instead of riding along a fence. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838339952-DY7GSFJGF024YGQF1MUR/IMG_9103.jpeg Emmet Build Pics The forearm portion had to be cut on the bandsaw to have a corresponding angle on the top end so it would align properly with the upper arm portion. I forget exactly how I marked the forearm for cutting, probably held it up at the correct angle and scribed it but I’m writing this 3 years after i did it, so I don’t remember precisely. For connecting it to the upper portion, I believe I also use a couple biscuits in here and then glued it up. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838349265-XIHGP7Q6ZIWWSUHIFTLB/IMG_9111.jpeg Emmet Build Pics Next up was trimming off the inner edge of the upper arm to create a flat surface where the arm would meet up with the torso cabinet. I’m not sure why this has a tie strap on it at this point, but I think at this point I had glued it but only snuck a couple trim screws in through the outside of the elbow joint. There were no screws on the inside (top edge) of the elbow joint, they were added later, so I think I used the strap to pull that glue joint tightly closed while it was setting up and until I could sneak a couple screws in later through the inside of the tube once it was trimmed off. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838350103-NPWXVIE94UKX20AYSLXV/IMG_9112.jpeg Emmet Build Pics For this one I did use a fence while going through the bandsaw, but I didn’t create a sled to hold it in place, I just freehanded it (sort of) again and took my time. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838354494-EUO2Q9M8PL5MXQB28033/IMG_9114.jpeg Emmet Build Pics With the portion trimmed off where it would meet the torso cabinet, the interior of the arm was more accessible and I believe I snuck a couple trim screws in from the inside to secure the two sections together. Again, I don’t remember exactly, but I sometimes use small T-10 trim head screws from GRK on my projects, and it was probably those I used here. After this I built up the top portion of the shoulder using layers of primed pine on edge, cut roughly into semi circles and stepped much like i did with the hair and head pieces. Then I filled the remaining opening (where the arm meets the torso) with a plywood piece in order to make the arm connection, which is shown later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838311508-44GS6DTTF6649C6CIRUR/IMG_9061.jpeg Emmet Build Pics I’m going to jump to working on the hands now and get back to the arms later. I ordered this large 3” diameter maple dowel from amazon for the wrist portion of the figure. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838316999-JJI3JMHN2I1R9TIWDUKX/IMG_9081.jpeg Emmet Build Pics The hands are essentially tubes that are trimmed off with a curved bottom, so I decided to build them up out of multiple rings of primed pine. I first cut square blanks, then trimmed off the corners into an octagonal shape. Then I built this jig to hold the octagons in place while I drilled out the center with a hole saw bit. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838322121-VVJLV5K5VDU4DFQJPR1O/IMG_9082.jpeg Emmet Build Pics This is one of the finished pieces of the hands. Multiple layers were glued together to build up blanks for the hands. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838322202-KFTBGTG4DUDVK9XBCVDH/IMG_9084.jpeg Emmet Build Pics From these pictures it looks like I used 9 layers of 3/4” thick primed pine for each hand, then I cut the openings on the table saw or bandsaw. After that I rough cut the bottom curvature using a bandsaw, then a lot of sanding to smooth everything inside and out, again using my oscillating spindle sander and upright belt sander. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838342824-5KRHVMBTUQ135U3PWP33/IMG_9104.jpeg Emmet Build Pics To attach the hands to the wrists, I drilled out a section in the back of the hands to fit the wrist dowels. I believe i did this on my drill press with a hole saw blade without any centering bit on it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838343764-PW4C5J5CZ4YQ5Q5X7U95/IMG_9106.jpeg Emmet Build Pics The hands are angled in comparison to the wrists, so I cut the ends of the dowel to a 15º angle. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838345599-LAG65KOXJDHN38TUQ4L9/IMG_9108.jpeg Emmet Build Pics The hands were attached to the wrist using glue, a couple brads, and a couple of those trim head screws as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838283994-KWDJC1ZAXX6DVD3J5GXV/IMG_3794.jpeg Emmet Build Pics The wrists also have a groove cut in them to accommodate a pair of set screws in each arm that hold the wrists in place while allowing them to rotate. These set screws were set into threaded inserts in the forearms. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838287765-4CELBOJKSXSKWAUJZ7OY/IMG_3796.jpeg Emmet Build Pics Doing a test fit of the arms to see how things look. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838310878-EOSJIEYA1BAB2DV9IKU1/IMG_9060.jpeg Emmet Build Pics At this point I had cut the curve in the top of the leg cabinet outer faces, and then trimmed the side piece of the “waist” torsion box to follow that curve, thus creating the look you see here of the typical upper connecting piece of a lego figure’s legs. The outer sides of the torsion box are double up with 2 pieces of primed pine, the outermost one gets cut to match the curve, the inner one remains intact so it sits firmly on top of the leg cabinet. I also added a central curved piece between the legs to resemble a real lego figure, it was a plywood disc with a flat edge that abutted the bottom of the torsion box I believe. If I remember correctly, this was attached to that bottom of the torsion box by some trim head screws run down into that center curved piece (I believe the torsion box was open on top, with some central ribs, and the torso cabinet was screwed down onto them. Not 100% on that, I’d have to check my notes to see if there’s more info). Judging by the screw holes in the front of that torsion box, I think it had no top and a bottom only in the center where that leg divider was attached. NOTE: I confirmed this later through other pictures, the torsion box was open on top and bottom except for a central bottom piece where the leg divider attached. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838316612-25M6OKVNO2OGGQZZMMK4/IMG_9076.jpeg Emmet Build Pics Jumping to the head now. This is the main central portion of the head, without the curved top and bottom sections. I built this using arcs like the one you see here cut from primed pine. I rough cut them out of primed boards on the bandsaw, then I believe I sanded them to the line using an oscillating spindle sander and an uprgitih belt sander. This could be done with a bearing bit on the router table, but given the change in grain over the course of this arc that would risk tear out and possibly breaking the piece, and I don’t remember that happening so I don’t believe I used that technique. The arcs were cut longer than needed (more than half the circumference of the head), and then I built a sled they were clamped into and run through the table saw to get that half-diameter length and parallel end cuts. After that I assembled them by staggering the joints between each layer, but I made sure that no joints would land inside the area where the door would be in Emmett’s face. I had marked that location on the first arcs and then kept track of it as I was moving upward. I don’t think the pieces here have been assembled, I think this picture is just a dry fit, however I believe I built up the center section like this and sanded the interior on the oscillating spindle sander, then attached the entire thing to the base and then put the top on . If I had built it up layer by layer on the base piece, I wouldn’t have been able to sand the interior easily, it would’ve been a nightmare to get smooth and I don’t remember that being an issue. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838354242-G8CDUAEN1CGTFNRYOLMR/IMG_9148.jpeg Emmet Build Pics Midway up the head I trimmed the interior of one of the rings to accommodate a shelf that would divide the head into two sections. The thicken portion on the right side is where the door will be in the face of the figure. If you zoom in on the lower portion of this photo, you’ll see the staggered joints between each half section of the arcs that I mentioned in the previous photo. Also by this point I’ve attached the bottom of the head, which was built up of wider cut rings of primed material at the bottom with a plywood disc inserted for the bottom “floor” of the head. I didn’t have primed material wide enough to make full circles, but I still needed to carve away at them and sand them into a smooth curve on the exterior, which is why I made those ring much wider than the ones that make up the main central portion of the head. I didn’t use plywood discs because sanding and carving them away would leave raggedy edges and possible voids, which would lead to more repair work later. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838357918-8SDONVY5E0AO0T4S3TKI/IMG_9149.jpeg Emmet Build Pics After the shelf was set in place, I continued building up more rings until I got to the upper portion of the head which was made from solid circles cut from primed pine just the bottom portion of the head. I also used a series of smaller circles for the neck. Note the area marked “No Glue”, this is the top of the door, and I was going to be attaching the upper wood circles now to make the top of the head. Leaving glue off here gave me a clean break for the door opening, and by doing the same “no glue” section at the bottom, all I had to do to get the door cut out was to cut the vertical openings on either side. I could have glued everything in place and then cut it out, but this way I could get a nice straight line at top and bottom with no risk of waviness from doing it by hand. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838359780-9BA6NELD5G7ANDG2AZFY/IMG_9154.jpeg Emmet Build Pics Here’s the head loosely set on the torso, again just to see how things looked. If you zoom in on this photo, you’ll see a vertical line on the left side which is where I’ll cut for the door opening. At the top and bottom of that line, you can see, closer to the middle of the head, the gaps where there is no glue that I mentioned previously. Obviously by this point I’ve attached the upper portion of the head, which was made in the same fashion as the bottom section. Wider rings of primed material that stepped in as I went up, and were later carved/sanded away into a smooth exterior arc, and then the center of the head is capped with a plywood disc set into that uppermost ring (visible in the next photo). Since this figure will have hair, that top plywood disc will be covered in the finished product. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838360720-JL23L2CYD339TSWMTMZP/IMG_9158.jpeg Emmet Build Pics The rings of the head had a number of voids, cuts, etc on the exterior after sanding, so I used drydex compound to fill them, which I applied by just slathering it on with my hands. Once dry I sanded it smooth again. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838364545-7EH3NAZK866KG4GS4D2J/IMG_9182.jpeg Emmet Build Pics Next up was cutting the door open. I only had one shot to get this right, so I took my time and used an oscillating cutter. This cutter also ensured that the gaps in the door would be pretty minimal. Again, I was only cutting out the vertical sides of the door since the top and bottom were already set with the unglued gaps I mentioned earlier. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838364968-ZEDZEPRSTM88Q22MD88I/IMG_9184.jpeg Emmet Build Pics The head with the door cut out and removed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838370468-FTUKDPKG6PLMOKTWJ9A2/IMG_9187.jpeg Emmet Build Pics Not sure if I had put the hinges on, or if this is just with the door wedged in place, but this is what it looked like when opened. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838375903-R0715SZKLLAJK5HMSLUY/IMG_9239.jpeg Emmet Build Pics Next up was building the hair, which I decided to make like it was sitting on top of the head like it does with a real lego figure. First step was to make a series of rings that were wide enough to fi over the main body of the head. These rings, and all of the hair I believe, were made from plywood arcs and discs because there were no primed boards wide enough to do it in one shot. As much as I would prefer carving and sanding on real wood as opposed to plywood, there was no other option that would have made sense. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838370678-ILBRCB1762MEDGGLREUG/IMG_9238.jpeg Emmet Build Pics After that I added plywood discs on top to build up the bulk of the hair, with the layers stepping in as they got closer to the top. They are stepped in so I don’t have to remove an excessive amount of material later when I’m shaping the hair. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838376884-L5KRM8CVGAAU4MCS6NQ5/IMG_9246.jpeg Emmet Build Pics Next I trimmed away the inner edge of the hair blank so it would not cover up the door opening in the face. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838380514-OWFAPCX5R08RGSIOKQOP/IMG_9247.jpeg Emmet Build Pics This is the hair blank sitting on top of the head. By this point I’ve installed some small hinges for the door. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838381720-34ZMB3I3RWOX2MWNROHJ/IMG_9251.jpeg Emmet Build Pics Using a series of measurements taken from the actual figure, I roughly sketched the shape of the hair and tried to eyeball how the top of the hair would curve over. I also made a line around where the hair was at its thickest point based on the actual lego figure, so I could know where to start carving away the upper layers into a smooth curve. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838384495-YAQR2MQNB2FZENIHQITA/IMG_9253.jpeg Emmet Build Pics I did the same thing on the other side. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838387216-RH0EKJ6IVV7X6U26CHWW/IMG_9271.jpeg Emmet Build Pics Back in the shop I cut the hair roughly to size using a jigsaw. I also made up this base where I could rotate the piece while I worked on it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838409340-ZLBAS0GTBR9APY6D0YFR/IMG_9372.jpeg Emmet Build Pics I spent a while spinning the hair and head to see where things needed to be trimmed. I would mark areas with a sharpie, then sand/grind them down and recheck how things looked. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838415152-6QWHCWDEWTBKEFI3Y0YB/IMG_9458.jpeg Emmet Build Pics Instead of trying to carve the cowlick out of the main body of the hair, I made it as an extra piece. Not sure what I made this from, I had some rough 8/4 pine stock in the shop back then, so it may have been from a chunk of that because this doesn’t appear to be built-up from smaller pieces. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838419861-BCSLYSS5I3ZF9K50RY6U/IMG_9461.jpeg Emmet Build Pics I bought a grinder attached, probably from amazon, and used it carve away the inside of the cowlick. I sanded it first on the spindle sander to get it to the correct arc, but it also needed to have some material removed along the long center line of the underside so that it would better conform to the curvature of the head, which is what I used this grinder attachment to do. I believe I also used that same attachment to grind away parts of the hair while I was shaping it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838415150-X5C49XB42VXX794THM16/IMG_9460.jpeg Emmet Build Pics This is the final bottom edge of the cowlick. Doesn’t have to be perfect as it was going to be glued in place and tacked, but I still wanted to get it pretty close so the glue connection was solid. Here you can also see where I had carved away the inside along the centerline so that it didn’t wobble when placed on the head and the outer edges sat as close to the surface of the head as possible when attached. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838420544-Y08986PWI82XBV9J4N2A/IMG_9462.jpeg Emmet Build Pics I also decided to draw on the face using sharpies I had in the shop. This wasn’t necessary at this point since it was going to be painted over anyway, but I wanted to see how it would look so again, I took some detailed measurements of the face and then transferred it to the full size head. This was when I felt like it was really starting to look like something. Also this turned out to be useful later as the sharpie showed through the yellow paint, and it was easy to retrace everything without having to make a mess of the paint with layout lines, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838426705-0FEZU85MOMVF2KSB4HEA/IMG_9465.jpeg Emmet Build Pics With the hair on I continued to sand and refine it, then I used the grinder attachment to carve the lines into the head from the original figure. This was just done freehand after eyeballing it and sketching some paths with a sharpie. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838427064-5B6058ET2VRURZ1I3VSZ/IMG_9466.jpeg Emmet Build Pics Looking at the backside of the head. I must’ve attached the cowlick shortly before taking this picture, because you can see the glue is still wet where it meets the head. I believe I tacked it in place and then added a few small trim head screws to secure it, you can see where I used the drydex to fill the holes on the cowlick. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838388238-IJQGCXS35XOB0K2Y4ASJ/IMG_9301.jpeg Emmet Build Pics Jumping back to the arms. I made the shoulder portion of the arms from a bunch of half circles cut from pined pine which I then sanded to a smooth curve for the outer edge. On the inside of the arm, I filled it in with a solid piece of 3/4” cabinet ply and then cut out a large keyhole slot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838392853-ZUD6P43XCC9VSENFGHVY/IMG_9302.jpeg Emmet Build Pics I wanted the arms to be able to rotate, so I came up with this keyhole slot and shoulder mount made from wooden circles joined together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838392913-TVEUMA77WLRGI449Y813/IMG_9306.jpeg Emmet Build Pics The joint drops into that keyhole slot and then slides up into the arm, allowing it to be securely hung while still being able to rotate. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838398107-4TLXCX4UCSB180598XPS/IMG_9309.jpeg Emmet Build Pics After test fitting the arms, I realized they wanted to fall in at an angle because that backer plywood circle on the shoulder mount was too small, so I made a larger ring that matched the outer diameter of the arm where it meets the torso. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838398438-ONT5G2AB2L8R4LJ91NPF/IMG_9311.jpeg Emmet Build Pics A test fit of the arm. Also, by this point, I’ve obviously sanded down the arm tubes, this was done using a standing belt sander and a disc sander, and probably some hand held sanders as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838403518-Q6Y1VLRIPBJX7VNU576K/IMG_9314.jpeg Emmet Build Pics Test fit of the body so far with both arms attached. At this point the arms only hang straight down. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838403896-DCXDSCOYDRF9HSV15WJ1/IMG_9319.jpeg Emmet Build Pics I wanted the arms to be positionable, so I embedded magnets into the outer ring on the torso side of the joint. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838408968-BA0867DFP0EC3N8M1YMM/IMG_9320.jpeg Emmet Build Pics Magnets were also set into the arm at corresponding spacing. The arms were fairly heavy, and due to the leverage of them, the arms wouldn’t stay in each and every possible position, but they would stay somewhat forward which I was happy with. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838432363-GXSD7XPD11ANQ7PABP17/IMG_9480.jpeg Emmet Build Pics Now that the main portions of everything are in good shape, I started painting everything. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838432458-3HMKPNB9FOHX8OVQ208L/IMG_9481.jpeg Emmet Build Pics Some items like the arms and hands were hung from the ceiling for painting so I could get all sides in one shot. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838437876-9ICK7EU948RL6O67CTIB/IMG_9487.jpeg Emmet Build Pics For the hair I recycled the shaping mount to be used as a painting mount. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838438367-URH51X7HU2TW2N2AKZNV/IMG_9498.jpeg Emmet Build Pics I attached the head to the body with glue and a few screws from underneath that went up into the neck. The hair is glued in place and secured with a few brad nails in the back. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838443131-BAD7EKH9Q58HA0LICGAM/IMG_9503.jpeg Emmet Build Pics Now it was time to add the details of the figure. first step was to layout for the reflective strips on Emmett’s vest and then tape them off and cover over everything else I didn’t want to end up silver. I used a reflective spray paint that I’m pretty sure came from Home Depot, most likely a Rustoleum or Krylon product. One note: I should have taped off the portion in the middle of the upper horizontal stripe so that it didn’t go all the way across. It should have stopped where the black edge details of Emmett’s vest come down. Since I ran it straight across, I had to paint the some of the blue portion of Emmett’s shirt overtop of that silver paint, and it always came through a little bit more than I’d liked, never quite got the blue color to be super consistent. Not a major issue in the finished product, but if I were to do it again I would make sure I only painted over the silver paint with black paint which had no issues. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838443519-4O290E9IDX4MNBXBR97Q/IMG_9504.jpeg Emmet Build Pics Here it is after spraying on several coats. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838448317-XBP8V4WWRAECF1CFAS7K/IMG_9506.jpeg Emmet Build Pics And with the tape removed. I don’t think I mentioned it before, but the doors for the torso cabinet were cut to follow the details on the original lego figure, that will be more obvious in the next steps, but it’s why the doors are unequal and angled at the top. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838448438-YE6Y8F9VXKXFHZP69N5F/IMG_9508.jpeg Emmet Build Pics Next up I added the face back on using a sharpie, and added the main outlines on the details. Here you can see how the doors follow the angle of the details on Emmett’s vest. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838452067-3VU3P8CQ52IVH3TQ4J2Q/IMG_9509.jpeg Emmet Build Pics I did the outlines in sharpie because it’s easier to get a straight line, but then I painted over them with black paint using a narrow artist’s brush. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838453667-30A6CHVHMSFIV1MTXSVD/IMG_9510.jpeg Emmet Build Pics Here all the detail outlines have been painted overtop of the silver reflective stripes. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838457228-H5ABA2GV99JP4TRLESL0/IMG_9511.jpeg Emmet Build Pics Next step was to fill in color as needed. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838461841-EE4YAGDQVN0GXNTO6JYZ/IMG_9532.jpeg Emmet Build Pics One last detail to add was Emmett’s name tag that is on his leg. I made a paper version printed to scale of what I wanted to do, then using a razor blade I cut out the design so I could easily follow it with a sharpie. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838462755-TP10UOII07K5Y6D5SGCV/IMG_9535.jpeg Emmet Build Pics Using a sharpie again to make the outlines, I also marked where portions needed to filled in solid black. Then I taped it off and added that silver reflective stripe. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838466680-NIFH0HKQFI60O8R4PAPP/IMG_9537.jpeg Emmet Build Pics After painting the black portions as needed, I filled in the remaining areas with a light grey paint I mixed in the shop (no records of amounts, etc, I just eyeballed it). This took a bunch of coats until the light grey areas looked good without any orange showing through. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838292037-TXIYHYX152H892KHK03T/IMG_3894.jpeg Emmet Build Pics The completed project. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838296215-HXSEPNOJ8D72VRODB6L6/IMG_3895.jpeg Emmet Build Pics With the doors open. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838458221-2R6FY0EPXWWLSO5Y2MWS/IMG_9515.jpeg Emmet Build Pics I didn’t mention this earlier, but I also added details on the back, including large circular indentations to mimic the look of a real lego figure. I made them using a handheld trim router and just took my time to make sure there were no mistakes. Tricky part was at the top of the legs where the cabinet top curves in. I believe I made that section by layering up primed pine again to create the transition from the plywood back of the case to the plywood top of the case. After it was fully sanded and curved, I used the trim router to create these indentations and just carefully followed the curve at the top of the legs. I don’t recall sanding any curved sections inside the cabinet case, so that transition piece was probably just set in on an angle and then I curved only the outer face of it. NOTE: I looked back and found in another picture (not on here) where you can clearly see the inside of the leg cabinet. The top goes back, then angles down at approx 45º to where it meets the back piece of the cabinet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838467032-H9WQN14S8GAAMA9PW4RL/IMG_9557.jpeg Emmet Build Pics The next few pages are a few of my notes, by no means all of them. i only took these photos because the kindergarten teacher (whose class I made this for) asked to be able to show some of the work that went into this project when displaying it at the school. This page is about how the head is constructed. Originally I had intended to make the lower portion of the head more spacious, but that required compound curves and eventually I figured it was more trouble than it was worth, which is why I used the solid wood circles for the lower and uppermost portions of the head. This also gave a nice flat bottom to the lower shelf when opening the door on the face, instead of having a drop down inside the head. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838471526-PHMO47HHOOZA9RNUWKEV/IMG_9558.jpeg Emmet Build Pics This is the original sketch I made when I came up with the project, a general idea of how the main body could open up for storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838471461-J03RZVSI3TAEVY5X17K1/IMG_9559.jpeg Emmet Build Pics This page has to do with the angles required to make the arm sections. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838475298-LLTV9YLIOPVOQRM0JDHV/IMG_9560.jpeg Emmet Build Pics This is detailing the wrist/hand setup and the set screws embedded in the arms. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838475713-JCYZ5JYH7F37BK7T9R0U/IMG_9561.jpeg Emmet Build Pics More detailed notes about the hands, angles relating to the wrist, etc. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838480778-1GFR59MFBHIKT7CCJP2O/IMG_9598.jpeg Emmet Build Pics After Emmet was finished I had to transport him to the school, so I wrapped him in painter’s plastic, then covered him with large contractor trash bags. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838488636-QMNIKHUB56Q6PIIMS7CZ/IMG_9774.jpeg Emmet Build Pics Then I wrapped the whole thing in a bunch of canvas dropcloths for more protection. By this point I had also obviously painted the base black. Also I had trimmed the bottom of the doors off slightly so that they wouldn’t scrape on the base when opened. Not sure at what point I did that, but judging by some pictures I have of the back of the finished project, the leg cases are sitting directly on top of that black base, no spacers at all, so it was definitely the leg doors there shortened slightly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737838488225-PCVVOD4LDOFE48QOFI83/IMG_9775.jpeg Emmet Build Pics Once it was loaded into my truck, I added more dropcoths around the base and tied it off to the shelves so it couldn’t tip over. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1737845905329-YVSRYINTV7V17OW0ZRXP/IMG_9822.jpeg Emmet Build Pics On display at the school awaiting the raffle. My wife had the idea to include a picture of Emmett opened up because she realized people wouldn’t understand it was also a cabinet, which turned out to be a great idea because a lot of people were shocked when they saw the photo. http://www.greengatewoodworks.com/wayne-mudroom-desk-1 daily 0.75 2025-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738786277385-RAZX9VGB1ATNNYJMTS30/IMG_9631+2.jpg Wayne Mudroom / Desk For this project the client contacted me looking to create a dual-function space in their front entry room. They needed storage for typically mudroom things (coats, etc) as well as a desk space for working from home. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738786271105-GGYR9Y3CKLFEIQVB2D3E/IMG_9805a+2.JPG Wayne Mudroom / Desk The finished project has full length hanging storage in the tall wardrobe cabinet on the left side, and split storage on the right side with interior shelves inside the upper and lower cabinets. The desk features storage drawers below and open shelving above, with a desktop made from quarter sawn maple sealed with a marine-grade varnish. Custom straight-cut wainscoting on the back wall provides an extra level of detail. The paint color is “Terrain” from Sherwin Williams (SW 9613) http://www.greengatewoodworks.com/merion-station-closet-renovation-1 daily 0.75 2025-02-05 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738787844741-XZH5EN94WT2I7MMZ7PU5/IMG_9436.jpg Merion Station Closet Renovation For this project the client wanted to increase the storage in their bedroom closet and make it more efficient. In order to create more space I removed the front wall of the closet and relocated the light switch to the adjacent wall. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738787836376-IPTLUICF8BROACV3EAFZ/IMG_9515.JPG Merion Station Closet Renovation The finished project takes advantage of the entire width of the closet, and is about 10” wider on each side now than the original layout, and about 11” taller. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738787851337-DYC4M9LYC9RH8YDZHIFR/IMG_9521.jpg Merion Station Closet Renovation The left unit has dual hanger bars, while the right side features shelves for storing smaller items and dual hampers below. Under-shelf lighting illuminates every section of the new closet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1738787860629-3PH7FMLPLZ6IPT43UEDD/IMG_9522.jpg Merion Station Closet Renovation The hampers pull out for easy access and are housed in solid maple drawer boxes. http://www.greengatewoodworks.com/kc-about daily 0.75 2025-08-13 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/2252a7c7-5ad0-42dd-9f51-af75ec3be814/KEC+7-8-2025+R62_1336+x-B-Sq.jpg <p class="" style="white-space:pre-wrap;">About</p> http://www.greengatewoodworks.com/new-page-50 daily 0.75 2025-08-13 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/28422a62-8d8e-4cdc-9989-f586d01dbe38/Screenshot+2025-08-13+at+12.39.08%E2%80%AFPM.png <p class="" style="white-space:pre-wrap;">Projects</p> https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/81abc958-a925-4073-91ba-55fc28ba1db4/Screenshot+2025-08-13+at+12.37.08%E2%80%AFPM.png <p class="" style="white-space:pre-wrap;">Projects</p> http://www.greengatewoodworks.com/kc-onboarding daily 0.75 2025-08-13 http://www.greengatewoodworks.com/my-mudroom-1 daily 0.75 2026-02-11 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844393484-AJAYRB3GWV0P2I3M6O2P/IMG_1419+2.jpeg My Mudroom A few years back I had installed brick floors in our mudroom along with lockers, cubbies, and a small bench, but the room remained unfinished for a while. In 2025 I was finally able to finish it up. The first step was to waterproof the dog shower prior to installing the brick floor and wall treatment. Thanks to Jeff Coppolino of Coppolino Construction for handling the installation of the dog shower pan, brick base, and the waterproofing membrane. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844399520-OHKQSY3H1LSU6YVL1QPY/IMG_1724.jpeg My Mudroom For the walls we wanted to do a tall wainscoting. Since the dog shower would obviously have to deal with moisture, I made the wainscoting in that area out of Azek (PVC boards), so that it would be completely rot proof. All joints in that area were sealed using a PVC adhesive that bonds the boards fully, making it entirely waterproof. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844398657-K6ZQ6PKCUH6V49T2IXY5/IMG_1723.jpeg My Mudroom Wainscoting was extended around the entirety of the room. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844462692-LLL0M1V6YG8X4TQ4MVYT/IMG_2008.jpeg My Mudroom After I had completed all the trim work and we finished painting the walls, my wife got to work stenciling. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844376389-6MNR7NVXSKK5LTD094AD/IMG_0665+2.jpeg My Mudroom The finished room turned out great, the stenciling added a really nice touch. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844382510-8E0K47Z5URN5ZXHHJWER/IMG_0695+2.jpeg My Mudroom Hooks around the room allow for plenty of hanging space, and the hooks inside the dog shower come in handy for towels or even hanging up raincoats to drip dry. Flagstone for the wall cap and shower threshold, provided by LS Stone Masonry Solutions, created a nice contrast to the surrounding bricks. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844386950-J7DS6GZCSYPMGJ6AT84M/IMG_0701+2.jpeg My Mudroom A new mirror was added along with some smaller hooks below for keys, leashes, etc. The new black entry door offsets the light colors of the trimwork and walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844375585-AYSKXAA4DVS5A6FVB2EU/IMG_0633.jpeg My Mudroom My daughter was a big fan of the dog shower. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770844380879-FFI907SQZPHCEVXOHZ11/IMG_0672+2.jpeg My Mudroom Sydney the dog was not as enthusiastic. http://www.greengatewoodworks.com/green-gate-woodworks-new-shop-1 daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859338972-WWTCYFBQBTR8X9033JII/B85B93CF-65CF-45F7-BB51-3EDCEF946258+2+copy.JPG Green Gate Woodworks New Shop After many years working in a small two-car garage, I decided to build myself a new shop so I’d have more room and could make my work flow more efficient. I ordered a timber frame barn kit from Brooks Post & Beam and worked with them to customize the design to my requirements. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859486064-QAB3AFW6XQRXU4GE7924/IMG_7517+2.jpeg Green Gate Woodworks New Shop This was my original shop. Because I needed to still have access to my machinery and equipment while the new shop was being built, I came up with a plan to build around the existing shop and enclose it within the new one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859507434-TUGLJM9UBGQXURQY5HVC/IMG_7662+2.jpeg Green Gate Woodworks New Shop First step was to remove the front overhang of the roof so I could begin excavating. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859484259-R6FVZH932N2OJTTP5HM7/IMG_7510+2+copy.JPG Green Gate Woodworks New Shop I did the bulk of the excavation with my little tractor and backhoe attachment. Most of the new shop would extend behind and to the left of the original building, here I am excavating for the new floor area. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859549543-C55822GZ9SA69EIK0K5I/IMG_8076+2+copy.JPG Green Gate Woodworks New Shop For the footers I had to rent a mini excavator that allowed me to dig deeper and closer to the original building than my tractor could. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859565452-PNEKRJLNBQ6OYKKQGBMF/IMG_8091+2+copy.JPG Green Gate Woodworks New Shop After excavation was complete and rebar was installed, it was time to pour the concrete footers. The skid steer makes short work of pouring the concrete and is far easier than pushing wheelbarrows around. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859570145-RGAU2EONMOBE2YMGU7U8/IMG_8103+2.jpeg Green Gate Woodworks New Shop Once the footers were dry, I was able to start laying the first course of cinder blocks for the new foundation walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859606541-K28F29A3BBOLOJWN0RLT/IMG_8193+2.jpeg Green Gate Woodworks New Shop After many hours of masonry that made me appreciate my woodworking job more than ever, the new foundation walls were up and surrounding the old shop. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859495615-5UWAR1JHHPPDN0RIC4PO/IMG_7644+2.jpeg Green Gate Woodworks New Shop The timber frame kit arrived shortly thereafter from New Hampshire. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859337395-88Y2CNCKNEHL3SXJTZUA/580C4D08-21CB-4C2D-A8A5-61A9D552A13B+2+copy.JPG Green Gate Woodworks New Shop For unloading the truck, I got to learn how to drive a new toy, the Telehandler, also sometimes called a Lull. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859606888-XE1MBFOJPSGPL8J23LTD/IMG_8257+4.jpeg Green Gate Woodworks New Shop The timber frame kit was designed to go just above the walls of the original shop, so we removed the shop roof framing and tarped everything to keep everything dry inside. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859619149-Z7WK3XJ445821MOPWQAN/IMG_8299+2+copy.JPG Green Gate Woodworks New Shop First post going up. Because the new framing had to pass over the shop while still landing at the correct height so the interior stairs would lay out correctly, it was important to get this first post set to the exact height required. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859619206-9KC5RN66IZ5OE9JADE8X/IMG_8303+2.jpeg Green Gate Woodworks New Shop Once we had our heights established, it was quick work framing the front wall. The timber frame kit is cut to exacting standards and went together perfectly. Since it was just myself and my helper Tom on this project, I set up my Genie, or material lift, on a pallet that was then strapped to the tractor. This material lift has an electric winch on it which made raising and setting the large framing members much easier than doing it by hand. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859394916-ZEAZO12LS5TI5VHP41TA/IMG_3448+2.jpeg Green Gate Woodworks New Shop However, since the tractor was tied up with the material lift, we had to muscle the framing pieces to wherever the tractor was. Not fun on a cold somewhat muddy job site, but there was no room in the budget for a second tractor. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859394068-OI39UNVRNOW9EZDX43M3/IMG_3450+2.jpeg Green Gate Woodworks New Shop Setting the rear walls. I installed a remote control on the winch on the material lift so I could operate it from up on the ladder while we shimmied the beams into place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859404868-YV0RWGY1T8BA8HGT076Z/IMG_3454+2.jpeg Green Gate Woodworks New Shop The entire timber frame kit goes together with minimal hardware, mostly its old school draw bore joints where a peg is hammered through slightly offset holes in the framing pieces to draw everything together tightly. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859638064-KR95XX49XXMIT97ZDV7R/IMG_8333+3.jpeg Green Gate Woodworks New Shop First floor timber framing complete. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859651998-16FA78GEGJ727HUQNK0Z/IMG_8404+3.jpeg Green Gate Woodworks New Shop Next up we installed the second floor deck and began to frame the knee walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859662753-6EKRXLTW5CIQBNGW0HMS/IMG_8459+2.jpeg Green Gate Woodworks New Shop Here you can see the main posts for the roof going in. We used the material lift to load all our necessary materials up to the second floor before dismantling the lift and moving it up there as well. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859665139-IQL4RH8PBSG0NSNNN99C/IMG_8472+2.jpeg Green Gate Woodworks New Shop With the material lift on the second floor, we began setting the ridge beam sections. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859675385-K71K9Z26RS4R1WVB6VWY/IMG_8479+2.jpeg Green Gate Woodworks New Shop Once the ridge beam was set, we used the material lift to help drag the rafters up into position before securing them in place. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859686867-YRLN7VCNB4R8Z1YOL3YV/IMG_8496+2.jpeg Green Gate Woodworks New Shop With the rafters in place we installed the in-fill framing on the first floor for windows, sheathing, etc. We also put some tarps up on the roof to help keep the rain and snow out. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859424885-OI6IVPVM559XJ69XSILL/IMG_3521+2.jpeg Green Gate Woodworks New Shop Here you can see the original shop inside the new one. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859700563-0K9ITM71AZGQPXNM0L1U/IMG_8560+2.jpeg Green Gate Woodworks New Shop Next up we installed the second floor in-fill framing and then started on the sheathing. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859336374-8FX232UMMFY43VMPXHXR/22A56B07-6FAE-4251-AE48-F11FB2553080+2+copy.JPG Green Gate Woodworks New Shop The roof consists of a layer of 2×6 framing covered in Zip Wall sheathing. In this picture I’m racing to get everything closed in before a snow storm was supposed to hit, and to keep myself secure I broke out my old tree climbing gear and tied myself off to the nearby maple tree so I could move around safely without risk of falling. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859464035-S97KJ6MAZL1LPOGMYCLP/IMG_6986+2.jpeg Green Gate Woodworks New Shop Once the sheathing was installed and taped, everything inside was pretty well protected from the elements and I was able to start installing windows and a pair of temporary doors. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859465342-9PKBIK1RPJWK8GCR21OE/IMG_7106.jpeg Green Gate Woodworks New Shop While it wasn’t in the original design, my wife and I decided a pent roof across the front of the barn would look nice and would provide some protection for the new front doors I had in mind. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859375406-CTQI44A2XGCIF9GJVLYT/IMG_2546.jpeg Green Gate Woodworks New Shop Meanwhile, inside the shop I had removed the original shop walls, poured concrete for the new floors, and framed the staircase. The area under the stairs provided an opportunity to create a little space for Sydney the dog. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859375311-XT3ONH4CE50NX1RD9WKZ/IMG_2612.jpeg Green Gate Woodworks New Shop Sydney in her dog house https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859528650-XSVWYKX8E5D85VH9CFPD/IMG_8024+3.jpeg Green Gate Woodworks New Shop To replace the temporary set of front doors I had made, I found these reclaimed doors that were the perfect width for what I needed but were around a foot too tall. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859575336-MFYYKVOVUBMTPNVPEMXW/IMG_8117+2.jpeg Green Gate Woodworks New Shop So I rebuilt the doors to the new height I needed. It’s a little more complicated than just sawing off the bottom of the doors if you want to maintain the structural integrity of the doors, to see this project more in depth click here. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859724851-CD6OL7CZC0HOCMDP8KWT/IMG_8896+2.jpeg Green Gate Woodworks New Shop With both doors rebuilt to the correct height, I gave them a fresh coat of paint and installed them. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859739856-M138WMX1HF52EPKJGQLC/IMG_9155+3.jpeg Green Gate Woodworks New Shop New doors installed, plus capping on the barn is complete and I installed standing seam metal on the pent roof to match the metal roof on our house. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859356668-VLBOCQWPZ7QX9G1BBSBG/IMG_1230.jpeg Green Gate Woodworks New Shop For siding I installed ABM panel metal siding from AB Martin in textured evergreen color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770859358851-DYNPPOV7NR8482GH4PGH/IMG_1263.jpeg Green Gate Woodworks New Shop Completed siding on the side and back walls. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770902438933-FWTE4W385E3H1GVLYPUG/IMG_1267.jpeg Green Gate Woodworks New Shop The “finished” shop as of the summer of 2025, next up will be installing gutters and then stone around the bottom of the walls to match our house. http://www.greengatewoodworks.com/my-kitchen-1 daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906693483-LWWKCVEDI7XU64OT0VBV/Screen%2BShot%2B2020-06-06%2Bat%2B10.24.11%2BAM.png.webp My Kitchen This is an elevation I drew prior to our kitchen renovation so I could show my wife what it would look like when it was finished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906677980-PTZJ84LP2TL8FES617JY/1217%2Bkitchen.jpg.webp My Kitchen The installed kitchen. I made all the cabinets, doors, and drawers in my shop. Eventually there will be a peninsula along side the last cabinet on the right which will have a butcher block top and will serve as a prep area for when I cook. The countertops in the picture are temporary plywood ones. I milled rough lumber from a maple tree on our property and will turn that into wood countertops once it is dry, which should be sometime in mid-2018. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906678044-BVCWIF5TXNDWGN73QYV4/1217%2Bkitchen%2B2.jpg.webp My Kitchen My younger daughter supervising me while I work on the kitchen installation https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906679567-N42ZIINYEYBPGDCGUJHQ/1217%2Bkitchen%2B4.jpg.webp My Kitchen These are the pull-out shelves my daughter was sitting on in the last picture. Typically I make my drawers with dovetail joinery, but in this case I wanted to do something different, so I made them from solid maple with a housed rabbet joint in each corner, and then pinned that joint with walnut dowels. These pull-out shelves hold all my cast iron pots and pans and function perfectly under that heavy load. This design worked so well I started to include it in all my built-in projects for clients who wanted drawers or pull-out shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906680659-1HEGM04C1HD5BNDA0SDM/1217%2Bkitchen%2B5.jpg.webp My Kitchen Part of the kitchen renovation included finding a place to keep our trash cans. I decided to utilize some dead space over the basement stairwell and made this recessed cabinet. With trash can on the bottom, paper recycling in the middle, and a container for bottles and cans up top, each container pulls out on drawer slides for easy access and emptying. The doors open either with traditional pulls (which were on backorder at the time of this picture), or you can push the doors in slightly which triggers a magnetic catch to push the door open if your hands are messy. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770906679490-FZFOZO8V9AH6T476BI3P/1217%2Bkitchen%2B3.jpg.webp My Kitchen When I installed handles on the trash cabinet doors, I also installed a smaller pair down low for my kids to use. Here my younger daughter tests them out. http://www.greengatewoodworks.com/newtown-square-dining-room-builtins-1 daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770909755945-GOO8Y0X4WB52F2392I3C/IMG_0072.jpeg Newtown Square Dining Room Built-ins This dining room built-in dry bar with wine fridge and fridge/freezer drawers serves as an extension of the adjacent kitchen for entertaining. The overlay, double-stepped, shaker doors and simulated, divide-lite, glass doors with custom, stepped grids were made to match existing kitchen cabinetry. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770909760301-V0V0PP8QWL3KH0BDF1WJ/IMG_0073.jpeg Newtown Square Dining Room Built-ins Under-cabinet lighting illuminates the black walnut countertop, and the LED lights on top create a nice ambient glow. I also replaced the existing kitchen cabinet lights with new LEDs, so all lighting is uniform in color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770909766322-PKQP36KSTXBLH9NMGT3J/IMG_9951.jpeg Newtown Square Dining Room Built-ins “Before” pic http://www.greengatewoodworks.com/glen-mills-mudroom-1 daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770911204540-400H666YAQJ9L05G492Q/IMG_0511.jpeg Glen Mills Mudroom I enjoyed working in this 1700s home to create an equestrian-inspired mudroom. Larger than my typical mudroom projects, this one wraps around the entire room and provides lots of space for large storage cabinets and plenty of hanging area. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910925529-MKU6MD5YW3TOGVEGGXCN/IMG_0510.jpeg Glen Mills Mudroom I spent a good bit of time during the design phase making sure the various sections of the cabinet face frames and doors would align and flow together visually. It’s a subtle detail that will mostly go unnoticed; however, it was worth the effort because without it, the cabinetry would feel discordant. The main wall of cabinetry shown here has open storage below for baskets, and the cabinet on the far right extends behind the adjacent wardrobe, providing an additional 24” of storage, utilizing what would otherwise be dead space in the corner. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910893594-39H5LXYNORMGLXQDQC99/IMG_0498.jpeg Glen Mills Mudroom Black walnut - featured on the bench top, countertop, and backer boards for the hooks - was chosen to complement the floors and paint color. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910902739-8Y8U88C48F3Q1D9MUL7I/IMG_0502.jpeg Glen Mills Mudroom Custom wainscoting ties the various sections of the room together. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910930995-2ZB7U4DIIHZ9O42CIY3B/IMG_0512.jpeg Glen Mills Mudroom The rustic bridle hooks the client provided are a fantastic detail. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910914298-B01F50HRM17Z33MZ92KL/IMG_0506.jpeg Glen Mills Mudroom This wardrobe cabinet features hanging storage up top and two pull-out shelves for shoes in the lower portion. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770910785366-2UX4M0ISK7OD19TWK0NP/IMG_0400.jpeg Glen Mills Mudroom “Before” pic http://www.greengatewoodworks.com/phoenixville-entertainment-center-1 daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770913133914-G6JIVBFPQFQVSG4X1KXN/IMG_2576.jpeg Phoenixville Entertainment Center This living entertainment center features inset doors, a black walnut countertop, and upper shelving surrounding a central frame TV. Below the TV is an open area which houses the audio equipment and speakers, which are hidden behind a fabric covered front. That front is mounted on magnetic push latches, and will come forward for removal after being pressed inward. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770913418865-GOSQ0T7NOF9XLJ4QPBY2/IMG_2571.jpeg Phoenixville Entertainment Center Under-shelf LED lighting provides a warm glow to the room without creating glare on the television. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770914559285-D2W21G0RBNI7XE1S12YH/IMG_5305+2.jpeg Phoenixville Entertainment Center After I was finished the client was kind enough to send me this finish picture of it fully decorated. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770913115739-SOSWY3SCD6CD44WN2VEM/IMG_2439.jpeg Phoenixville Entertainment Center “Before” pic http://www.greengatewoodworks.com/merion-station-bedroom-builtins-1 daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916042941-RRUKF7KPLCHJOFNOTOL3/IMG_1194.jpeg Merion Station Bedroom Built-ins This project for a repeat customer consisted of three distinct pieces spread out across a third-floor bedroom with very tight access up the stairs. All of these cabinets had to be brought in disassembled, then rebuilt onsite. This first unit is a built-in dresser with loads of drawers for storage and open upper cubbies. All carpeting in this area was to be replaced which is why I gave myself a little extra room when removing it. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916034045-LE3SK4IF5P0N50X4O7C8/IMG_1075.jpeg Merion Station Bedroom Built-ins “Before” pic https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916047155-U5SRWU4GPJJIB2PR1N3B/IMG_1195.jpeg Merion Station Bedroom Built-ins This recessed bookshelf was added along side an existing closet. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916032564-200HFGO6UAUSKW8J2MEB/IMG_1074.jpeg Merion Station Bedroom Built-ins “Before” pic https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770917062172-Q0NI56RSU0FRV8MQQ7CC/IMG_1199+crop.jpg Merion Station Bedroom Built-ins This angled bookshelf unit sits on top of an existing HVAC soffit that was in the room. Instead of trying to reroute all the ducts inside, I turned it into a window seat with a beautiful black walnut top, saving both time and money. Access was so tight coming up the stairs that the black walnut top had to be loaded in through the window. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770916036857-WPO0EXDMTET1CW3DZTM5/IMG_1097+2.jpeg Merion Station Bedroom Built-ins “Before” pic http://www.greengatewoodworks.com/merion-station-builtin-bed-closet-and-dresser daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919071215-9H9S77MS632D9GQHCGQX/IMG_1833.jpeg Merion Station Built-in Bed, Closet, and Dresser This project consisted of a built-in bed with bookshelves at the foot- and headboards, plus a closet unit, and a built-in dresser. Drawers under the bed and below the footboard provide additional storage. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919060721-ZLO1B4LJL28B6IO6AVLC/IMG_1824.jpeg Merion Station Built-in Bed, Closet, and Dresser Undershelf LED lights in both sets of bookshelves create a soft light for reading. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919059828-NA9IKLYBY1ANKCXSPM6Y/IMG_1823.jpeg Merion Station Built-in Bed, Closet, and Dresser The closet unit consists of an upper hanging area with open storage below. The client was handling painting the walls and ceiling themselves, which is why it’s cut in along the walls but not finished. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919354576-HRHARFS8DPSK310JUNVJ/IMG_1836.jpeg Merion Station Built-in Bed, Closet, and Dresser The shorter footboard allows for an extra shelf compared to the headboard shelves. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919053064-BMYUIDRRBEC78QO0OKQR/IMG_1424.jpeg Merion Station Built-in Bed, Closet, and Dresser “Before” pic https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770919053070-2XGX4A1KXIZZKZJNFP82/IMG_1422.jpeg Merion Station Built-in Bed, Closet, and Dresser Another “before” pic http://www.greengatewoodworks.com/new-page-1 daily 0.75 2026-02-12 https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770921830665-U89DY9I5XWA4O40JOJ2X/IMG_3059.jpeg Merion Station Bedroom Closets and Window Seats A repeat client came to me with this project for their master bedroom. They wanted to replace their original Ikea wardrobes with something more permanent that would give them additional storage. The door knobs and drawer pulls were on backorder when I completed this project which is why they are not shown. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770921849275-VGF049WG405KGPV9PR96/IMG_3061.jpeg Merion Station Bedroom Closets and Window Seats All three closet units have hanging storage of varying lengths. The center unit has mid-length hanging storage, the right side has slightly shorter hanging space with an extra pull-out shelf behind the doors. The left side closet’s two upper drawer fronts are false, concealing a full length hanging area behind them. The false drawer fronts create a standard appearance across the entire project despite the varying hanging storage areas. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770921847501-4QKXSA8763JN266NDODY/IMG_3048.jpg Merion Station Bedroom Closets and Window Seats All three closets have LED lights inside controlled by a motion sensing dimmer in the ceiling, which illuminates the hanging areas when the doors are opened. https://images.squarespace-cdn.com/content/v1/577c5a6715d5db726ef510c0/1770921818638-R2RD9QLSLHBSVYTCF2TB/IMG_2795.jpeg Merion Station Bedroom Closets and Window Seats “Before” pic