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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.

Gallery

Comments

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351 Posts
Pretty amazing! I am still working on getting to that level of workmanship.
 

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19,716 Posts
Just when I think you have impressed me beyond belief your next post tops the last, fantasticly wonderful
 

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123 Posts
CLAMPS!! Yikes! You must have a forest's worth of handscrew clamps in your shop!

Your work really does impress me.
 

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73 Posts
wow, I don't think even Norm Abrahm has that many clamps… all I can say is OMG what a process…
Great work, the trim is exceptional…
 

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31 Posts
Cool picture.
 

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1,748 Posts
Exactly how many clamps do you have???? holy cow
 

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Glad its you not me! Amazing work you did there:)
 

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30 Posts
What kinda molder is that?
 

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"we made it it" outperforms in regard to tight and changing radius, head size is critical for the issue of hit back. We run very deep and wide profiles "U S Concept is great stuff"
 

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70 Posts
Yes, that IS a bunch of clamps. I know. I helped put them on….and on….and on. :) Somewhere in the neighborhood of 450 on this glue-up. And we didn't use all he has!

It really was cool to see just how this is done - start to finish.
 

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1,487 Posts
Next time my wife says I have too many clamps I will have to show her these pictures. Very impressive.

God Bless
tom
 

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WOW never seen that many clamps! Great work!
 

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315 Posts
Special!
 

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Wow you did a beautiful job on that senior center. I know you got this comment before, Wassss up with all those clamps? I have one question, where do you store them . Awesome work.
 

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156 Posts
Fantastic job!
 

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100 Posts
Amazing, looks to take a lot of experience and technique, can I borrow a clamp, just kidding
 

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156 Posts
Fantastic work. I hope the senior center i get dumped in is one you worked on. LOL

I hope Troutguy Is not the better typist cause he has the most fingers.
 

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220 Posts
Very nice, very, very nice. What molder was being used? Also - did you purchase your clamps by the gross?
Awesome job!
 
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