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Building a House in Kala Point, Port Townsend, WA

Building a House in Kala Point, Port Townsend, WA
A running narrative of first-time builders of their retirement home in Port Townsend, WA (NE corner of the Olympic Pennisula, 60 miles NW of Seattle). Follow us as this adventure unfolds in late 2008 and beyond. 18 months under construction, we moved in on May 25th, 2010. Photo taken August 15, 2010.

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Tuesday, March 13, 2012

Custom built cabinets, Spring 2012

In keeping with the now occasional posting to the blog, its time to report on some custom cabinet building that's going on in our home. The Den is the main object for cabinets. When we built the house, we left alcoves on either side of the fireplace, which occupies a long wall. Also, on the opposing shorter wall, we wanted to put up a large wall bookcase. We'll, I'm happy to report that at least the wall bookcase is done and the built-ins are underway.

We decided to build the cabinets out of fir, to match all the trim in the house (windows, doors and baseboard). You'd think that fir would be cheap and plentiful--NOT, at least good clear vertical grain (cvg) fir. 1x stock is easy to find, but expensive compared to paint grade woods, and most times the vertical grain of the wood is only displayed on the face, not the sides (the 1x part). So you have to be a bit careful, or laminate the edges with cvg strips.

Plywood is another matter. At Edensaw, our local quality wood supplier (mainly to the marine and furniture businesses around PT), 1/2" and 3/4" two-sided, A-grade cvg fir plywood goes for about $125-145 per sheet. YIKES. Even 1/4" ply for the back of cabinets is nearly $100 per sheet, so you can see how a cabinet can eat up some serious money quickly. There are less expensive options, like using one-good sided plywood, melamine 1/4" ply for backing, etc. but you end up with an IKEA looking cabinet when you're done. Conversely, its a bit comforting to know that you'll be saving thousands (yes $1000's) of dollars in professional labor if you have the woodworking skills and tools.

The wall cabinet that I've finished is about 8' wide, 7' high and 12" deep. Mainly designed for displaying art objects and some books and magazines. I basically built four 2 ft-wide boxes and ganged them together. Then I built the face frames in places, using 1x stock that I had already prefinished with clear, semi-gloss polyurethane. This type finish is easy to apply and dries fast (hours), and is good away from water. Two coats on a 220-grit sanded surface, then light sanding with 220 or 400 and a finish coat usually is all that is required. I fill nail/screw holes , then spot finish the filled hole before the final coat.

The tops and bottoms of the cabinets are trimmed out with a craftsman-style detail that I picked up from a coffee table in this same room. It has a series of square holes (spacing is 1-1-1-1-3-1-1-1-1) centered in each bank of the cabinet, with an arched base. To finish the whole unit off, I built a piece of crown molding that matches that used on the kitchen cabinets. After 2 years of building, I'm actually starting to understand you can integrate a concept by carrying themes and styles throughout the house, furniture and art items. So we have a Craftsman house trimmed with cvg fir, salmon, and ginkgos. We added LED lighting bars (12" long,$30 @ IKEA) behind the face trim at the tops of the cabinets, with a remote control device between the outlet and lighting. Just flick on the small remote and you get some nice mood-lighting on the glass shelves.


I kept track of the labor and cost involved in this first cabinet, although I knew the outcomes before I even started. Basic materials were about $600 for wood, $50 for finishing, and $115 for 8 glass shelves. The project timed out at 78 hours (OUCH), or almost two full weeks. I suspect a professional could do it in about half the time, but at $40/hr (a cheap furniture builder), the labor would bill out at $1600. So that would be $2400 for the 8 ft wall bookcase. Now I don't feel so bad about the material costs.

I started the two built-in cabinets this week. They'll take about the same time and materials as the first bookcase since they are both 4-ft wide. The cabinet on the left side of the fireplace will house the TV and media equipment, whereas the one one the right side will be for books. Four drawers across the center of the cabinets will house our soon-to-be collection of CDs. There will be one large speaker on each side, a left over from the old days of free-standing speakers. They are B&O's, which I traded for a semi-prof bicycle back in the 70s (that's a separate story).

Subcontractors and Suppliers

  • Balco Excav. (land clearing, Bill Snyder)
  • Bill McCutchen's Mill (cedar trim)
  • Blake Tile and Stone, Sequim (Judy Reno, Eldorado Stone, Tile)
  • Bob Brown Plumbing (Bob & Josh Brown)
  • Boise Cascade joists (from Carls)
  • Carl's Building Supply (Mike, Melissa, Michele, Terry & Lawrence)
  • Castlerock Landscaping (Tim Hamm, Sequim)
  • Cotton RediMix (concrete and gravel)
  • Craighead Electric (Gary Estes)
  • Custom Hearth (propane fireplaces), Pousbo
  • Daltile (Seattle, Wedi board)
  • Discount Cabinets of Washington (Sequim)
  • Discovery Bay Materials (gravel, top soil)
  • Earl Kong (professional forester, PT))
  • EcoHaus (Amer. Clay Plaster, cork flooring)
  • Ellis Construction (Gary and Troy Ellis, framing)
  • Evergreen Products (Drywall, Sequim)
  • Fergusons, Seattle (Plumbing fixtures, Bud Allen Wright)
  • FInlandia Saunas (Tigard, OR)
  • Fitzgerald Concrete (driveway, Mike Fitzgerald)
  • Four Corners Nursery (trees, Port Hadlock)
  • Frank Feltes Custom Drywall and Painting (drywall and painting)
  • Frank Ward and Wayne Jobst (Stone masons)
  • Fredricks Appliances (Redmond, all appliances)
  • Giraffe Gutters (Dan Shaw, Chimicum)
  • Glass Etchings by Perrett (Jerry Perrett)
  • Hadlock Building Supply (bits and pieces)
  • Hardiboard, siding, backer board (from Carls and Home Depot)
  • Henerys Hardware (Cabot stain, misc. fasteners)
  • Hi-Tech Electronics (Audio & Media, Port Angeles)
  • Hide-A-Hose (Joseph, A-B Vacuum, Puyallup, WA)
  • Home Depot (electrical & plumbing supplies, interior paint)
  • Home Storage Solutions (John Plake, PT)
  • Hope Roofing (Pabco Paramont Advantage shingles)
  • Jim's Tool Time (J. Quandt, misc. carpentry)
  • K&D Concrete (Don McNeese)
  • Kitchen and Bath Studio (Shelly Little, cabinets)
  • Levi's Energy Services LLC (radiant design, vents, propane piping)
  • Meta Marble and Granite (travertine), Seattle
  • Michaelangelo (sepentinite), Seattle
  • Mikael Brostrom (Structural Engineer)
  • Mills Interiors (wood flooring, some tile)
  • North Coast Electrical (Electrical Supplies)
  • Olympic Garage Doors (Sequim)
  • Penisula Flooring (carpet)
  • Penisula Shower and Mirror (Sequim)
  • PexSupply (online plumbing and radiant supplies)
  • Puget Sound Power (and Atelco installers)
  • Richard Berg Architects (Richard and Darlene)
  • Richard Gifford Construction (septic, dry wells and grading)
  • Richerts Marble and Granite (countertop fabricators)
  • Seattle Lighting (lighting fixtures)
  • Secret Gardens Nursery (Sheila Piccini)
  • Shine Quarry (basalt for landscaping)
  • Sierra Pacific Windows (Rob Sorg)
  • Simpson Doors (from Carls)
  • Simpson Strong Tie (fasteners & hold downs)
  • Stewart Excavating (Mark Stewart, foundation)
  • Sunshine Propane (propane and tank)
  • Therma-Tru Doors (from Carls)
  • Tracy's Insulation (batts and blow in)
  • Trex Decking (from Carls)
  • Trussworks (roof trusses, Carl's)
  • Velux (Skylights and Solar tubes, Carls)
  • Versalam beams (from Carls)
  • Warmboard (Bruce Hull)
  • Wisbo Aquipex, Taco Pumps, Polaris tank (Sunshine Propane)

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About Me

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Professional geologist (USGS, 1972-2008), amateur home remodeler and now builder. Interested in sailing, all things involving salt water, woodworking, and food in general. Owner of Paleo Seis Surveys LLC, consulting in Quaternary geology and geological hazards.