Houston Hardwoods Custom Moulding and Matching Services
Houston Hardwoods is your local lumber yard located right here in Houston providing great service, great prices, and solid experience you can rely on for your custom moulding project. Over our 34 years in business we have matched or custom created a huge number of moulding profiles for our customers (we currently have around 3,000 profiles in our database!). You can can count on us to partner with you to deliver the custom moulding style you’re thinking of or match an existing profile you have – all with an extremely quick turnaround time! Want to see what we’re talking about? Click here to jump straight to some examples of us creating and matching custom moulding for customers that they could no longer find anywhere else.
1. Understanding the Need for Custom Moulding Profiles
Before diving into the technicalities of milling, it’s important to understand why custom or profile matches are often necessary. Architects, designers, builders, and renovators may require custom moulding profiles to:
Match existing moulding in a restoration project
Moulding profiles that builders use or stores carry change over time. What was once a popular profile can be discontinued and replaced with a new variation. When you need to replace sections of moulding in a restoration project, matching the existing good sections and maintaining the same style might be the best solution for you! In fact, with over 3,000 profiles in our database we might already have your profile in our database. Click here to check out our database or ask us if we have already have your profile.
Create unique profiles that meet specific design requirements or achieve a look that isn’t available from stock mouldings
Have a vision for your project but can’t find a profile to match the look you’re going for? In addition to matching, we can create custom moulding from a sketch. We’re the perfect partners to help you achieve the custom moulding look you’re going for!
2. Identifying the Moulding Profile
The first step in matching a moulding profile is identifying the exact shape and dimensions of the profile you want to replicate. This involves:
Profile Tracing or Scanning
If the moulding exists and needs to be matched, bring a small section by our shop. We can use a profile gauge to create an exact outline of the mouldings shape. We also may trace or scan the profile to help capture all of the dimensions, curves, and angles of the moulding, allowing for an accurate reproduction.
Creating Custom Moulding
If you aren’t matching an existing profile come by our store or send us a sketch. If sending us a sketch we will want you to provide accurate dimensions of the moulding. If you’re coming by our store we would enjoy the opportunity to sit down with you to make sure we sketch out the vision you have in mind.
3. Creating the Knife for Custom Moulding
Once the moulding profile has been identified, the next step is to create a cutting knife that will shape the wood into the desired profile. Knife-making is a critical part of the process, as the precision of the knife determines the accuracy of the final product. You may be familiar with the process of how common keys are duplicated, this process isn’t all that much different. If we’re matching to an existing profile, we may already have the correct knife in our database, we have around 3,000 already created!
3.1 Knife Blank Selection
The knife is typically made from high-speed steel or carbide. These materials are chosen for their durability and ability to maintain sharpness over extended periods. High-speed steel is often used for wood moulding because it offers a good balance between cost and performance, while carbide is harder and longer-lasting but more expensive.
3.2 Knife Grinding
Once the knife blank has been selected, the next step is to grind the knife to match the profile of the moulding. This is done using a knife grinder, which is a machine that grinds the steel into the desired shape. The grinding process involves:
- Transferring the Profile: The profile is transferred to the knife blank using a template or a drawing of the profile. This ensures that the knife will cut the wood to the exact specifications required.
- Sharpening the Knife: After the profile has been transferred, the knife is sharpened to ensure that it will cut cleanly through the wood. This step is critical for achieving a smooth, accurate finish.
- Polishing the Knife: Once the knife has been sharpened, it is polished to remove any burrs or imperfections. This step ensures that the knife will cut the wood cleanly and smoothly, without leaving behind rough edges or marks.
4. Milling the Custom Moulding Profile
With the knife prepared, the next step is milling the wood. Milling involves running the wood through a moulding machine equipped with the custom-made knife. The machine shapes the wood into the desired profile as it passes through the cutter head. Here at Houston Hardwoods we have a large selection of lumber for you to choose from or let us know if you’d like our recommendation for your project.
4.1 Wood Selection
Choosing the right type of wood is crucial to ensure that the moulding is durable, stable, and aesthetically pleasing. Different woods have different properties, such as hardness, grain structure, and moisture content, which can affect the final outcome of the moulding.
- Hardwoods like oak, maple, and cherry are commonly used for moulding because of their durability and fine grain.
- Softwoods like pine or fir may be used for less intricate moulding or where cost is a primary consideration.
- Moisture Content: The moisture content of the wood is critical. Wood that is too wet may warp or shrink after installation, while wood that is too dry may be brittle and difficult to mill. Ideally, the wood should be kiln-dried to a moisture content of 6-8%.
4.2 Setting Up the Moulding Machine
The moulding machine must be carefully set up before milling can begin. This includes:
- Installing the Knife: The custom-made knife is installed into the cutter head of the moulding machine. It must be securely fastened to ensure it doesn’t shift during the milling process.
- Adjusting the Machine Settings: The machine settings, such as feed rate and cutter speed, must be adjusted based on the type of wood and the complexity of the profile. Slower feed rates are used for more intricate profiles, while faster rates may be used for simpler designs.
4.3 Milling the Wood
Once the machine is set up, the wood is fed through the machine, where it is cut by the knife into the desired profile. This process requires careful monitoring to ensure that the moulding is cut accurately and without any defects. Common issues that can arise during the milling process include:
- Tear-Out: This occurs when the wood fibers tear rather than cut cleanly. Tear-out is more common in woods with uneven grain or when the knife is dull.
- Burn Marks: If the cutter head is running too slowly or the wood is fed too slowly, burn marks may appear on the moulding.
- Warping: If the wood is not properly dried or the machine settings are incorrect, the moulding may warp during or after milling.
5. Matching the Custom Moulding Profile
Matching an existing moulding profile is often more challenging than creating a new one, as it requires an exact replica of the original profile. After milling, the new moulding is compared to the original to ensure a perfect match. This involves:
- Visual Inspection: The new moulding is visually inspected against the original. Any differences in shape, size, or detail are noted, and adjustments are made as necessary.
- Dimensional Comparison: Calipers and other measuring tools are used to ensure that the dimensions of the new moulding match the original exactly. Even small variations can be noticeable once the moulding is installed, so precision is key.
- Test Fitting: In some cases, a small section of the moulding may be test-fitted on-site to ensure it blends seamlessly with the existing moulding.
5.1 Fine-Tuning
If the moulding does not match perfectly, the knife may need to be adjusted and the wood re-milled. This can involve making small changes to the knife’s shape or adjusting the feed rate of the machine. Fine-tuning is often a time-consuming process but is necessary to achieve a perfect match.
5.2 Examples of our Custom Moulding
Check out some of our work creating and matching custom moulding for some of our customers!
In the below custom moulding examples we duplicated a huge 11-3/4″ crown moulding, matched some oak hand rail, matched a plinth block, and duplicated another existing trim item. You can see every step of the way we are ensuring a perfect match and fit to give you the perfect custom moulding for your project. We can match or create whatever custom moulding you have in mind!
Conclusion
The process of milling and matching a moulding profile is a detailed and meticulous task that requires precision, skill, and deep knowledge of woodworking techniques. That’s why Houston Hardwoods, with over 34 years of experience, is the perfect partner for your custom moulding project. Whether you need to replicate intricate historical details or create unique custom designs, we have the expertise and tools to deliver exceptional results. Check out our database and contact us about your project.
In addition to our custom moulding services, Houston Hardwoods provides a range of other milling services to meet all your woodworking needs. We mill to your specifications any of our lumber species (S2S, S2S1E, S4S, SLR1E, Sanding, Resaw). Our shop is equipped to handle custom cutting, surfacing, and shaping for projects of any size. Plus, with one of the largest selections of lumber in the region, you’ll find the perfect wood for your moulding or any other woodworking project. Whether it’s hardwood, softwood, specialty wood, exotic wood, or plywood, we carry a large variety of lumber types in all different kinds of sizes and prices. Houston Hardwoods is your local lumber yard conveniently located off W 34th Street. We are your trusted partner in quality materials and craftsmanship for all of your Houston lumber needs.