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How Giant Clamshells Form

This massive entryway above a Rhode Island beach was inspired by nature, but built by hand

What do you get when you combine the design of Ronald F. DiMauro Architects; the CAD and construction work of New England Woodworking; the carving, detailing, and layout work of Stephen Plaud Inc.; and the installation and finish work of Kirby Perkins Construction? A giant clamshell, of course. And a masterfully crafted one at that.

The clamshell, perched atop the entry of a Rhode Island beach house, is made from 19 layers of 2-1/4-in. thick pattern-grade mahogany and took the quartet (all of which are based in the Ocean State) 300 man-hours to engineer and build. But, don't worry, watching a slide show of the shell's painstaking construction will only take you a minute or two. We've also included a detailed drawing of the project and show you the carving tools you'll need, should you attempt a giant clamshell of your own.
Mahogany corbels (a) support a 2x framed tray (b) that is wrapped with a mahogany cove (c). The mahogany shell (d) is capped with arched trim details (e) and (f) and protected by a 2x framed roof (g).Mahogany corbels (a) support a 2x framed tray (b) that is wrapped with a mahogany cove (c). The mahogany shell (d) is capped with arched trim details (e) and (f) and protected by a 2x framed roof (g).
Measuring 12 in. by 50 in. by 51 in., two painted mahogany corbels support the coved tray and shell.Measuring 12 in. by 50 in. by 51 in., two painted mahogany corbels support the coved tray and shell.
Lead flashing protects the shell, the tray, and the pergola’s horizontal surfaces.Lead flashing protects the shell, the tray, and the pergola’s horizontal surfaces.

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Photos by Chris Ermides
From Fine Homebuilding 188
July 1, 2007
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