Hi,
After tearing off the “remodelled” boxed in porch on our 1884 farm house, I’m retro-fitting it back to something close to original. I want to fabricate the multi-layered brackets and arches I see on other original homes in our neighborhood.
I know that this trim was originally cut out in separate layers then laminated up to give the impression of highly carved masterwork. My question is – what is the most reasonable material to use? A friend suggested Baltic Birch Plywood – but I’m worried about my ability to finish the cut ends nicely, and it’s durability outside in the weather here in Wisconsin.
Any help would really be appreciated – by the way, here’s a link to the demolition and part of the reconstruction:
http://www.slash5.com/porch.htm
Thanks in advance,
Doug Jacobs
Replies
I'm doing a similiar thing and after looking at all the alternatives, I've decied on using Azek cellular PVC. I'm in the process of making the templates for the router table now and I'll use the Azek glue to hold the layers together. I plan on using some alignment jigs to hold the layers when I glue them up, because the pieces can "creep" a bit if you just try to clamp them.
One issue with Azek (or any cellular PVC) product is that you will see the "cells" when you route it. So you need to plan on filling them in. I think primer and paint will work, and probably some consolidant like Abatron or West system.I've also heard that paint lifetime might not be that great, though I consider the source of that somewhat suspect.But I've never tried any of the above. Just passing on what I have heard.
Yeah, I'm planning to paint. I don't know about primer though. I'll have to check the Azek site.
Make them out of redwood. Nice and soft to make sanding the sawn edges easier and faster.
Or make them from Western Red Cedar. Pricey, but great for use outdoors. Or you could get similar brackets from one of the many companies that make gingerbread/trim work.
Renaissance Restorations LLC
Victorian Home Restoration Services
http://www.renaissancerestorations.com
Others have suggested redwood and cedar but I cant find either of those woods reasonable. The cedar will be knotty as hell and the redwood will be pricey as hell.
You should be able to find cypress easy enough and its not that expensive, mills fine as well.
Doug
Stay away from the baltic birch plywood. It is NOT an exterior product- it's an interior cabinet-grade plywood.
I guess I'd go with redwood, but of course, here in California, it's not so outrageously expensive that you couldn't use it on the decoraative elements. Remember, you don't have to use all clear heartwood. Mixed sapwood is fine, as are tight knots.
Use of actual woods will give you architectural porch details that age appropriately.
I will have to second what ed has said about using actual wood as it will age correctly, even though the wood we are using now would probably be considered culls when your old house was being built.
I have done this often and used redwood, It may be expensive where you are at but you will over time forget the initial cost and only see your correct exterior details.. with other products you may find yourself looking at them and wishing you had not cheaped out.
james
Medex.
Its MDF but the MFG claims superior weather resistance to regular MDF. I would completely seal all surfaces before installing to be safe
Extira is another exterior MDF, similar to what you suggest. I guess it depends on what the lumber yard decides to carry.
BTW, Extira is from the same company as MiraTec trim boards
Sounds like an interesting project. How about posting a pic of a house (or website) that has something similar to what you want?
I have to do some arches for some proch railings in a month or so and, to tell you the truth, hadn't given much thought to how they would be made... I think azek entered my mind, although I'm not so sure that routing will be part of the plan.
Last summer we restored a couple victorians homes and I had to make a bunch of these......
DON't use the plywood, you wanna use solid stock. We used a lot of 1x and layered it up.
If you aren't that great with a routor, or are in a hurry, you can even buy your molding in the trim department at your local big box, and you make make some decent stuff with that.
I know this isn't preferred, but I have made quite a few from pine......it was paint grade stuff though......... I did some oak too, but that was way too hard to work.
Cedar works great but costly.
When in doubt, get a bigger hammer!
The great majority of the wood exterior trim in this area (close to 80%, I'd say) is white pine. It holds up very well as long as it receives normal maintenance. It's also pretty easy on the pocketbook and very easy to work with. And it takes stain quite well as long as you hit it with prep-oil first.
The other option is red cedar, which won't rot even if you don't paint it for 40 years. It is available in grades right up to CVG if your wallet extends that far. But unless you need a lot of it, the total cost won't really be that much.
To fabricate the brackets you're talking about, I'd use solid lumber rather than laminating up thinner pieces. It will save you time and trouble in the long run. Cut it with a bandsaw running a very narrow blade to help make the tight turns. You should be able to use a spindle sander to smooth out the sawmarks everywhere except inside the tightest cutouts, where you'll need a strip.
Dinosaur
A day may come when the courage of men fails,when we forsake our friends and break all bonds of fellowship...
But it is not this day.