The real long way
around the barn.
WE ONLY KNOW ONE WAY.
Whether we’re working with newly sawn or antique wood, we apply the same scrutiny in selection and time-honed craft in production. We are passionate about finding and reclaiming material that’s seen another time. Because each unique board or beam holds an expansive story of a place and a time that didn’t happen anywhere else. And it’s just waiting for us to unlock its secret. It takes more work, but it’s the only way to make something for you that no one else can have.
We're constantly scouring the country for beautiful structures made of wood that otherwise would be torn down or left to ruin. Our mission is to shape these materials into products for your home where they begin their new life as future heirlooms.
Once the old structures are dismantled into beams and boards, we use our hands, our eyes, and hand-held metal detectors to identify any metal fasteners in the wood. It's an arduous process, but by hand is the only fully effective way.
Next we set to work with a hammer, chisel, nail removers and the occasional torch to get all the nails, bolts and screws out of the boards. Sometimes all three types of fasteners can be found in the same piece of wood. The all need to be removed as saw blades typically only want to cut wood.
Reclaimed wood and newly sawn wood both spend time in the kiln, which acts like a convection oven to reduce the moisture level of the wood. This process also rids the materials of infestation and fungus that may be present, but cannot be seen with the naked eye.
Salvage material, once de-nailed, sometimes needs to be sawn to a new thickness before being processed into it's next stage of life. At the saw, this wood is "re-sawn" from a 2x or 3x piece of material or bigger beam, into a small dimension of thickness.
After we de-nail, the reclaimed boards and the occasional set of new lumber enters the kiln. At this point in the process, whether the material is reclaimed or newly sawn, it is guided through a spiral-headed planer to make each board the correct, consistent thickness by cutting from the top and bottom.
Next, the boards are processed through the rip saw. The rip saw is collaborated to produce planks of a consistent width by cutting wood from both sides, producing a straight “BLANK".
The moulder is responsible for processing the wood into it's final dimensional, predominantly adding a tongue to one side, a groove to the other and finish milling to the top face along with relief cuts on the bottom of the floor board.
Moulded boards then move on to the cut phase. An up-cut saw is used to square up the ends and dispose of unusable material.
Once the ends are squared up the planks are tongue and grooved on the ends of the planks. This assists with installation and it eliminates the need for the installer to cut each plank on the ends to square them up.
Sand & Finish
Sand & Finish - For any pre-finished floor, we fill voids larger than a ¼” of an inch. If a texture is desired it is processed at this time, for example wire brushing or hand scrapping. We then sand the flooring in order to apply the finish of your choice; water – based, poly urethane, or hard wax oil.
Planks are grouped together in like widths, nested and fastened together with plastic straps. This makes it easier for shipping and off loading.
Local deliveries are made on our company truck. When shipping commercially and out of state, we bundle, strap, and wrap in cardboard & plastic to ship on custom built pallets. We take every precaution to ensure safe delivery.
There are many methods of installation with different sub-floors requiring different processes. We are happy to assist you with our knowledge and expertise in regards to installation. Successful wood flooring installations allows your floor to begin its new life in your home, and thus history continues.