by Douglas Bialor on September 14, 2010
Few things can have as powerful an effect on the feel and function of a space as a well designed and well crafted built-in. The ability of a painted wall unit or bookcase to transform a space is remarkable. We should know, we’ve been taking our own before and after photos for over ten years now. We’ve also been refining our use of select materials, finishes, and processes to create the finest work possible.
Our Materials
We’ve found that, most often, the best material for constructing our cabinet and door frames and other solid wood parts is soft maple. Despite it’s name, soft maple is considerably harder than pine or poplar. This means it is much less likely to suffer dents and dings. It is also quite resistent to warping and twisting and is remarkably smooth, providing an excellent surface upon which to apply paint. Large panels are often best made from MDF(read more about MDF and other panel materials we use here), which is immune to the cracking and splitting that can occur within large areas of solid wood as a result of seasonal changes in humidity. Using MDF allows us to construct a stronger cabinet component that will last longer and look better over time compared to solid wood.
Finishing At It’s Finest
The quality of the painted finish is a major part of a successful built-in cabinetry project. Working in our dedicated finishing area, we create a high quality and extremely durable finish by employing a labor intensive process involving multiple stages of priming and sanding, followed by several coats of Benjamin Moore’s Aura Satin Enamel. Aura is a premium water-based finish that provides a lustrous feel. It is a remarkable paint, similar to a quality oil based enamel, but eco-friendly and non yellowing.
A Note On Pricing
There is a widely held notion that painted cabinetry is a less expensive option than many natural wood finishes. While this may have been the rule at one time, it no longer holds true. There are many functional and attractive natural woods that can be used for built-in projects at a lower overall cost than a painted finish. There are also many exquisite woods that can be used for built-in projects at a cost considerably higher than a painted finish. The reason for this is simple: labor. The single largest component in the cost of a project is the labor of the skilled craftsmen we employ to construct and finish each piece. And while the cost of paint grade materials may be slightly less than some furniture grade species we’d recommend for a clear finish, the difference is more than offset by the added cost of the labor required to produce a long lasting and beautiful painted finish. We believe this is a good thing, in that allows us to offer a wide range of options to fit every budget while encouraging the selection of materials and finishes based not on cost, but on design considerations.
Making It Happen
From concept and design, to fabrication and installation, the Hat Factory team possesses the knowledge and skill that will make your painted built-in cabinetry project a success. For more information, or to discuss your project, give us a call at 914.788.6288.
by Douglas Bialor on May 25, 2010
This dining room wall-unit was a fun project. The before and after photos are a great illustration of how to successfully resolve a couple of common design issues that we encounter on a regular basis. As you can see in the before photo (below), an existing structural bump-out in the right hand corner makes it difficult to place a piece of furniture against the back wall and contributes to the space feeling smaller than it really is. The existing sideboard cabinet, pushed all the way to the left side, ends up calling more attention to the problem than it does to fix it. Our solution was to replace the free standing cabinet with a wall to wall built-in that defines a consistent plane across the room. In addition to providing a centered focal point, it also offers increased storage and a more open, larger sense of space.

by Douglas Bialor on May 10, 2010
Another topic from the list of questions we get asked a lot is what type of wood should I choose for my project? This can seem like a daunting task, and one not to be taken lightly. After all, the entire success of a project can be jeopardized with the wrong choice of material. Fortunately, there are many great woods to choose from, and by evaluating some basic criteria it can become an easy and risk free decision to pick the right one. The criteria we use include, but are not limited to, the following:
- Cost
- Availability
- Durability
- Tone
- Texture
- Special Considerations
I’ll discuss cost, availability, and durability here and come back to the more subjective issues of tone and texture in later posts.
Cost & Availablity
There are many high quality woods that are suitable for the making of quality furniture and cabinetry. Some of the most popular that come to mind are ash, maple, oak, cherry, mahogany, and walnut. These are all readily available, stable, and highly attractive woods that are ideal for most interior woodworking projects. And, while costs do vary from species to species and exceptions must be made for highly figured and prized boards, this core group of materials is available at reasonable cost. In fact, because such a large percentage of the cost of any custom furniture or cabinetry project is the labor of the skilled craftsmen creating the piece, the cost of the material is rarely the determining factor in choosing a material. This is actually good news because it means that we can focus on choosing our material based on appearance, not on price.
Durabilty
While traditionally divided into categories of hardwoods and softwoods, these lumber classifications have more to do with the cell structure of how a particular species than they do with the strength of toughness of a particular wood and offer little practical advice on what might be an appropriate material for a given project. In truth, almost all hardwoods and mahoganies are suitable for furniture construction. While special consideration may be given to particularly durable woods, such as maple or oak, for projects that will be subject to extra abuse, all of our standard hardwoods will hold up just fine.
Tone & Texture
Next time we’ll discuss “tone & texture,” which are the terms we use here in the shop to define the color and appearance of a particular wood. These are the most important criteria in selecting a material for each project, and our unique approach ensures we can help you pick the perfect material for yours.