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Tour The Factory
Please glimpse into our carving vault where thousands of hand-sculpted oak and walnut works of art from the early 1900's reside. They stand ready to be used in creating fresh production moulds for our composition ornament line. The new moulds will capture the same spirit, detail and wood grain that are evident in these hand carved originals.
On the production floor of our compo ornament shop, a caster inspects a composition casting fresh out of the mould. An old world bookbinders press was used to press out the cast, which will be sliced from it's excess skin after an hour of cure time. It will then harden for several days at room temperature before being packaged and shipped.
In the cabinet shop, a craftsman assembles the wood bodies, or sub-structures, for capitals and brackets. Practically all of the wood items from this shop will go on to the composition ornament shop to be embellished with highly detailed ornament. Our mantels, valances, pilasters, finials and furniture legs also begin production in this shop.
At the mounting table, a wood capital is embellished with steam applied compo ornamentation. These ornaments have a glue matrix within and can self adhere to wood when they are steamed on a porous stretcher. This steaming process will also render the parts flexible for use on curved surfaces.
Our plaster shop is known for it's great attention to detail and commitment to quality. A craftsman is shown here extracting a hand cast pilaster capital from its flexible rubber mould. After curing or drying for 4-7 days, the casts will be ready for use.
The final step for production from all three of our shops is the careful packaging of items for shipment. Here we see a plaster niche shell being crated for shipment. Environmentally friendly wood based excelsior is used in our cartons and crates to prevent breakage during shipping.