|Project by Radiuswoodguy||posted 05-26-2010 04:45 AM||4368 views||6 times favorited||29 comments|
We were brought in to make all of the curved parts – crown molding, panel molding, and curved S4S for the entertainment room at a local senior center. The first two pictures show the some of the curved crown in place, as well as some of the panels. Some of the panel moldings are compound curves (curved wall and curved top). The third picture shows the curved crowns in the shop, before the backs were cut. Pictures 4 & 5 show the forest of clamps required for the glue-up. The last picture shows what we started with. We had a little bit of this 8/4 poplar left when we were done.
All of the curved parts are cold laminated (Thank God Roo Super Glue comes in 55 gal drums!!!) on custom cut trusses (patterns). We make paper templates after the curves are framed, and then make the trusses to fit the template. There are NO true radii in either the room or the moldings. We make them to fit. Period!
Glue-up and cutting the profile is just like installing crown molding – everything is upside down and backwards.
Here is a video pamorama showing all nine of the curved crown blanks in the clamps.
This video shows one of the curved crowns going through the molder.
And finally, a video walk-around the room after they’re installed.
All of these moldings are stock profiles, matched exactly. Total time to produce the crown molding was 2 days—sometimes 2 people, with other jobs going while the glue was drying.
TroutGuy typed this up for me (and helped clamp them up, and helped resaw the stock, and helped guide them through the molder), ‘cause he’s a better typist.