Deep in our core there is a desire to continually learn and expand our capabilities so our clients receive the highest level of craftsmanship…always with obsessive attention to detail. Our fine woodworking group, NEWwoodworks, has some of the most woodcraft obsessed folks you’ll ever meet and they love a new challenge. Enter CNC technology. As this technology has evolved, the NEWwoodworks team has pushed the capabilities of their 3-axis CNC router to better meet their high expectations.
Stepping up NEWwoodworks already notable capabilities is “Thelma”, a Thermwood CNC MTR-30 5×10 3-axis router. Much of their work is done with reclaimed timbers and board stock so a raised z-axis to accommodates the larger timber stock, additional table reinforcement and stiffer axes to aid in cutting denser material and an upgraded vacuum table to make complex jigging and complicated hold-downs easier and faster are all incorporated into the CNC.
What does this integration mean? Some of the rough cutting work and sculpting work can be hogged out by the CNC, then finessed and finished by the artisan’s hand. It helps afford a level of speed and precision that while possible by hand, is difficult and time-consuming work. It can be the best way to get that fine detail after the rough-in, which really eliminates multiple shapings and sandings.
“The CNC allows us to be more productive, even with highly custom designs like our live edge cabinetry. It excels with, and really helps us on, the simple bulk work like plywood cab parts and solid wood parts and pieces, significantly reducing handling and touches,” shared Rob D’Alessandro, general manager of NEWwoodworks. “Complex joinery, carvings, curves, and even typical furniture parts can be created more quickly leaving our craftsmen free to focus their unique capabilities on details, fit, and finish.”
The stringers for this floating stair were cut using the CNC. Photo by Don Cochran Photography.
Doors are the transitional pieces, the welcoming elements, the barriers against intrusion—be it weather or other diversions—the room dividers, the separators of space. A high-crafted door is designed to function flawlessly and be in service for decades. Yet over time their movement and environment can impact aesthetics and usefulness. Our fine woodworking group, NEWwoodworks, has had the opportunity to restore doors of heritage, bearing, and beauty for a few special spaces.
Home at the Spa
Elements from an original carriage house in Rochester were carefully salvaged, including the main entry doors, for a local spa. Always believed to be arched, during removal it was discovered that the original doors were rectangular. They had hung for years behind an arched opening to give them the look of arched doors.
Original doors, site salvaged.
The craftsmen at NEWwoodworks, lead by door guru, Jay, were tasked with creating arches in the old doors, along with general restoration. The doors were constructed in a traditional way using wedged tenons which were hammered in from the side. This type of old craft construction would close and tighten all of the stile and rail joints. With skill and care, an arch was cut in the doors and components were re-fitted to create truly arched doors. The surface was then wire brushed and mounting hardware was set into the backs of the doors so they could be hung on a wall.
Today they greet patrons from their new home where they live as pieces of art behind the spa reception desk.
Though species and finishes play a large role in the durability of wooden entry doors, time and weather will eventually wear through and some TLC will be needed to bring the wood back to life. A set of white oak entry doors on University Ave in Rochester, NY were removed by our craftsmen and transported back to the shop.
The original weather-worn oak doors on University Ave.
It was clear the bottom rails were beyond repair which lead the team to dismantle the doors and sidelights. Over 200 oak pieces and all joinery was restored. New insulated glass units and oil rubbed bronze hardware were added bringing a touch of modernization to the doors. Originally the oak was stained dark brown, but for this revitalization, it was requested to keep a natural finish to allow the oak’s patina to be celebrated. The craftsmen employed a polymerized tung oil that will be applied biannually as part of normal maintenance for the revived doors.
A fun find by a restaurant owner, this tall and slim pair of doors is believed to have originated in India before making their way to the US and eventually to the NEWwoodworks shop for a bit of care.
The doors were sinch-nailed together, nearly 3″ thick, solid white pine covered in layers of paint and signs of age.
Original, as-found pine doors.
The first step was stripping off the hardware and cleaning up the grills. A light wire brushing was applied to the surface to remove some of the rotten paint while highlighting the hard-earned surface character. Structural repairs were required in the moldings and some of the rails, but overall these doors were fairly solid. Frosted glass, new hinges, and a dead bolt completed the overhaul. Today the doors conceal a closet while acting as wall art. Their grills and glass are backlit, warm and captivating in the eatery’s entry foyer.
Rejuvenating and repairing, bringing new life and new love to these timelessly authentic doors are stories we’ll tell for many years to come. They’ve influenced and inspired new doors (below) and reminded us of old high craft techniques. See the gallery of door creations here.
Inspired by the adjacent antique doors, the new main entry door for the eatery entrance was crafted of Reclaimed Heart Pine by NEWwoodworks.
Earlier this year we talked about hardware that our our fine woodworking division, NEWwoodworks often uses. Today we’d like to share a bit more on the use of reclaimed wood by this talented group of craftsmen.
We like to say: if you can dream it, they can make it! Curving staircases that become gradually more narrow; displays with wooden double helix features; curved and arched doors; corner cabinets; end-cut tops; live edge steps, tops, stiles, and rails, to name a few – all crafted with reclaimed wood.
Crafted of reclaimed oak, these custom chapel doors are both arched and curved to match the curving exterior wall.
Reclaimed wood inherently has more character than fresh sawn, with ferrous staining, nail holes, deep patina, original saw marks, and high contrasting grain patterns. For our craftsmen access to Pioneer Millworks’ entire inventory of salvaged reclaimed and sustainable wood is no small advantage when searching for that one special board. Each antique board is hand selected and fitted for a one-of-a-kind creation.