Complex Maple Crown Moulding - Need Help!

[Dave Fifield]

Hi Folks,

I hope you are all recovering nicely from your Holiday excesses! I have a puzzle for y'all to try and help me solve.

I have some lovely maple crown moulding in my kitchen. I need to make a few more pieces that match (for the laundry room). I'm stumped. I have absolutely NO IDEA where to begin to make the stuff - apart from getting in some nice 6" x 1" maple stock. I'm hoping that one or more of you has made something like this before and can give me a clue as to how to go about making some more of this complex moulding.

Here's a picture of the only spare piece I have. Note, one end has some damage, but I can get the exact dimensions off the other stuff that's up. Click the pictures to see the full size versions. The moulding is obviously cut from a 6" x 1" board (I can tell that much!!).

http://www.ubersprang.com/projects/maplemoulding_s.jpg (http://www.ubersprang.com/projects/maplemoulding.jpg)

I tried to draw the cross section of it to help - this has the "broken" end fixed:

http://www.ubersprang.com/projects/CrossSection1_s.jpg (http://www.ubersprang.com/projects/CrossSection1.jpg)

Where do I start? :confused:
HELLLLLLLLLLLLPPPPPPPP!!!! :o

:Dave F.

[lou sansone]

the easiest way is to have a set of knives made that will fit a W & H molder. there should be someone in your neck of the woods that does custom mill work who will have a W & H molder who can do this for you. I don't recognize this profile as a stock profile, so it is probably a custom profile. the other way is to try to build it yourself using a variety of router bits, but you will end up with at least 3 separate profiles that you can glue together to form the final molding profile. if you have the money, I would opt for the W & H molder option
Lou

[Jim O'Dell]

Dave, do you know who put up the moulding in the kitchen? If the builder or a remodeler, try finding them and asking. If Lou is right that it's a custom moulding, they probably use it a lot and do their own. I bet they could be persuaded to do a run for you. Might be worth trying. Jim.

[Larry Fox]

Dave, I agree with Lou that easiest might be a custom knife. However, if it were me I would let a molding shop do it as they will likely be cheaper in the long run as they are setup to do it.

I have had good luck with Old World in NY. They also have a huge online catalog and you might even get lucky and see your profile in there somewhere. They gave me a quote of ~$250 to make a custom knife that I was considering to give you a rough ballpark.

http://www.oldworldmouldings.com/

[Ben Grunow]

Around here the cabinet manufacturer usually makes and supplies pre stained crowns like that. See who made your cabinets (usally marked on drawer sides/backs or inside lower cabinets, somewhere) and call them up. The advantage would be that they could probably match the profile and stain job with no work for you. Disadvantage is that it wil probably be expensive.

Good luck

Ben

[fRED mCnEILL]

When I had to duplicate some moulding I bought a Magic Moulder that repaces the blade on your table saw. Bought a few sets of knives and was able to come preety close.

Fred Mc.

[Steve Wargo]

That's a piece of cake. All you need is a set of hollows and rounds and a pair of snipe bills and you could knock that out in an hour. Oh, sorry, I thought I was in the neander forum. Honestly, it's not a real complex profile. I would think that with a little planning, a large ogee, a small ogee, some creative table saw set up and a scratch stock (profiled scraper) and you could do it without puchasing a shaper cutter. good luck.

[Dave Fifield]

Thanks for all your replies. I did contact the original kitchen cabinet maker who supplied and fitted the moulding too. He said there is no more of it, sorry. He "found" it and was saving for just the right job, which was ours apparently. So, it looks like I'll have to either do it myself or find a local with a moulding machine.

I'll have a go myself first and see how I get on. I have been studying the profile a bit more today and can now see the order in which it could be done on the TS and router table, plus some manual scraping and lots of profile sanding.

I'll let you know how I get on......with pics, of course!

Cheers for now,
:Dave F.

[Kent Parker]

Hey Dave,

You might try White Bros. in Oakland. They are well known here in the Bay area for their molding and millwork. A quick look in their catalog found a similar molding # 1138-C that might partially work in that you could use 3/4 of it and make the remaining.

The last phone number I have for them is 510-261-1600

http://www.whitebrothersmill.com

Cheers,

Kent