A few weeks ago we delivered the last of the Plyboo Millwork to the Casa Q site. Last week, while delivering other millwork, we were able to see the site carpenters finishing up the install. It’s great to see it finally come together on site. We’re looking forward to seeing it again after the trades finish the final touches in the building.
Unloading the Mailbox Surround
Bringing the Mailbox Surround inside - a tight fit through the door.
Wall Panel Bundled up - placed for scale.
The first look at the Lobby installed - The trades are still onsite.
Looking over details
2nd Floor Bulletin Board is wrapped up!
Since our last update, we’ve completed the fabrication of all Plyboo elements. This post focuses on the Second Floor Message Center. We received approval on all finishes from the architects and have started assembly and finishing.
Routing for Tight-Joint Fastners
Ready To Glue the Return Panel
Preparing the seam at Second Floor Message Center
Second Floor Return Panel Assembled
Second Floor Upright with cleat system in place
Second Floor Message Center Assembled
Sealer Applied - scuffing and preparing for top coat
Our extra shop help is perfect for scuffing in those hard-to-reach places
Lower Portion in our spray booth
Finished & Assembled - Now to dis-assemble and wrap for delivery
Last week we began fabrication on the 1st floor bulletin board and began to assemble parts for the mailbox surround and 2nd floor message center. All the pieces are coming together nicely and we’re preparing finish samples for architect approval.
Don Gluing the dominoes for an extra-long panel
Extra Long Amber Panel Glued and Clamped - This piece is for the Mailbox Surround
Cutting 1st fl. Bulletin Board Miters with our Festool Track Saw
Setting Biscuits at 1st fl. Bulletin Board Miters
Clamping the 1st fl. Bulletin Board Together
Spring Clamps hold the Glued Returns at the 1st fl. Bulletin Board Frame
Unrolling the Cork
1st Floor Bulletin Board - Assembled and ready for Finishing
The mailbox Surround is coming together nicely
This shows the build-out behind the Q Detail Panel
Dry-Fit of the Q Panel with Chocolate Horizontal Grain Backer
Just a couple of Samples - The finish really brings out the color difference in the bamboo.
In the first Casa Q post we focused on the CNC Detail work. Later in the week we started fabrication on the 17' bench that will be in the 1st floor lobby. The Bench Top and Face were fabricated first because they require very precise lock miters at inside and outside corners. The lower portion is a straight run and will be fabricated towards the end of the project.
The bench is fabricated from 3/4" Vertical Grain Chocolate Plyboo over a 3/4" FSC Birch Plywood Frame.
You can learn more about FSC & Plyboo by visiting theses websites - or - clicking the links above.
https://us.fsc.org/
http://www.plyboo.com/
Bench Top Profile Laid Out in Birch Plywood
Bench Frame Assembled
Don Lays out the angle cuts
Cleaning Up The Edges
Top Pieced Cut and Mocked-Up
Clamping the Top Together
Checking Our Lock Miters at the Bench Face
Checking Lock Miters & Joint at Inside Angle of Bench Face
Dry fit of Face Pieces
Clamps at the 1st assembled section
Clamps holding the face piece in place as it dries
The large angled piece glued and clamped seperatly
The last piece to get clamped in place.
Bench Top Complete - The Lower portion will be cut at a later time.
All Content for Projects show the most current Progress Photos. To see the entire process for the project, select the category and project name.
For the last few months we’ve been hard at work finalizing all the details for this unique project. We’re fabricating all the millwork for the 1st and 2nd floor lobbies in a residential low-rise in Chicago’s Pilsen Neighborhood. This is our first time working on a LEED project & our first time working with Bamboo. The material used is Plyboo Brand ¾” Vertical Grain Plywood in Amber and Chocolate; the different colors and linear grain will complement the contemporary design of the lobby. The 1st floor lobby features: a detail panel with letters ‘CASA Q’ Cut out on CNC, a mailbox enclosure, 8’ wall paneling, a 17’ bench with floating geometric protrusions, and a coordinating message center. The 2nd floor lobby features 8’ wall paneling and a cork bulletin board.
You can learn more about LEED & Plyboo by visiting theses websites - or - clicking the links above.
http://www.usgbc.org/leed
http://www.plyboo.com/
Unloading the Bunk of Plyboo
Detail Panel Fresh off the CNC
Sanding the CNC Letters
Fred & Don Working on Slat Detail Mock-Up
Casa Q Detail with Slats Mocked Up
All Content for Projects show the most current Progress Photos. To see the entire process for the project, select the category and project name.
Hours: Monday through Friday 8a to 4p & By Appointment
Office: 219-365-1137
fredbarr_custom@att.net
