We do a variety of arch projects; however, this will be one to remember. The unusual aspect of this particular project was the size of the jambs. The customer came to us by way of a referral from a former customer pleased with our product. We are always grateful and appreciative for recommendations from customers …it is the basis we build our business on…service and quality.
Our customer is building an upscale home with 2×6 exterior walls. The home features circle top windows which require 6” arched jambs. There are several 12” and 8”interior walls in the foyer and great room area. There will be 5 case openings in this area featuring elliptical arches. After the addition of sheetrock…we will have 13” & 9” jambs!!! Standard construction would require a 4- 9/16” jamb…now you know the unusual part!!
The good news …the jambs and casings will be painted…this allows us to use sheet material. We will be using a double refined mdf product with a thickness of 1-1/8”.
The jamb components for the 6 windows and 5 case openings were layed out in our cad program. The following picture represents 1 of the 14 sheets (4’x8’) that were required to manufacture the jamb components. Each 13” jamb will take 12 pieces to arrive at the necessary width…each 9” jamb will take 9 pieces and each 6” jamb will take 6 pieces. Notice the ¼” hole placements in the drawing…we will use ¼” dowels to stack the components.
Our next series of pictures involve the jamb assembly. After the jambs are assembled, we will skim the surface with a spackling compound and sand until perfectly smooth. Notice the placement of the dowels as the components are stacked.
The casing used to trim out the jambs was 4” in width and just under 1-1/8” in height. We extruded the profile across a flat relief in our Cad program and sent the file to our CNC for machining (This was covered in a previous post…”Arched Jambs & Casings”). We used a total of 6 sheets to make the required casing… a total of 20 (4’x8’) sheets were used for this project.
The following series of pictures represent the completed project.