Loft Conversion
Hall Closet
Behind the Scenes - Loft Conversion
The elaborate front hall closet system, a collaborative effort of architects Lisa Shire (design) and Greg Rochlin (implementation), creates a mural of curves and colors spanning the 20 foot length of the vestibule. This system resembled an art project for fabricator Brian Dauphinee and required precise attention to detail in the finish carpentry stage.
To get started on this complex project, 3/8" stock Masonite™ faced doors were re-cut (or re-railed) to produce a trapezoidal rather than vertical shape for the 6' high doors that make up of the lower section of the closet system. The existing plum edges were removed and the doors were laminated on the back and sides. (Even with Masonite doors, the backs and sides need laminating to prevent warping.) The backs were laminated in white, the edges in black, and the face with the pattern. The pattern utilized seven different colors including beige, brown, blue, yellow, off white, gray and a metallic. A color chart denotes each color of Formica™ plastic laminate utilized to create the overall design and its placement in the scheme.
Greg Rochlin used a Computer Assisted Design (CAD) program to produce a full scale plot for each curve and numbered each one on a separate sheet. To help him transfer the curved form from paper to laminate, Greg sketched a layout for Brian to follow, illustrating exactly where each curve started and ended.
To make the templates Brian cut out the outline of each curve and glued it onto lauan. Once the curve was glued onto the lauan, Brian cut out the template staying off the line by an 1/8". He then belt sanded the lauan to get a true line. Using the template Brian then transferred the curve to the Formica. To ensure a precise seam, Brian needed to overlap the Formica and cut both pieces of laminate at the same time.
To make the cut Brian used a veining bit with a collar that rode against the template to hold it in place. Brian then applied a little contact cement and let it sit for about twenty minutes to get good and tacky. The template also served as a slip sheet to carefully seat the laminate in place. (Dowels could have been used for this purpose but the slip sheet seemed the wiser option as contact cement is very unforgiving once the two surfaces touch.) With the curve in place, Brian used a roller for a smooth application followed by a router to trim it in place. When complete, the doors are hung on a partitioning system. A functional mural is now in place providing closet space to spare!
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