Virginia sawmill operators

by Gepetto Millworks | Aug 19, 2025 | Harvest to Kiln

The Need for Custom Milled Lumber in Producing Historic Replica Wood Products for Homes, Hotels, and Mixed-Use Properties

Historic buildings tell stories of craftsmanship, architectural vision, and regional heritage. From stately homes with hand-carved moldings to grand hotels adorned with ornamental wood details, each structure carries unique character. When these buildings undergo restoration, expansion, or adaptive reuse, architects, preservationists, and property owners often face a challenge: sourcing authentic wood components that match the originals custom milled lumber becomes essential.

Standard, off-the-shelf wood products rarely replicate the intricate details, species variety, and precise dimensions required for historic replica wood products. Whether the project involves restoring a Georgian-era doorway, recreating Victorian gingerbread trim, or producing millwork for a mixed-use redevelopment of a historic warehouse, custom milled lumber ensures that authenticity, durability, and architectural integrity are maintained.

In this article, we’ll explore why custom milled lumber is indispensable for historic projects, the process behind its creation, and how it benefits property owners, architects, and developers working with historic restoration millwork.

Why Historic Replica Wood Products Require Custom Milled Lumber

1. Standard Lumber Dimensions Don’t Match Historic Profiles

Modern lumberyards typically stock dimensional lumber in standard sizes—2x4s, 1x6s, or 4×8 sheets of plywood. Historic builders, however, worked with different milling practices and often used full-dimension lumber with hand-planed finishes. Window sashes, stair treads, or door stiles from the 18th or 19th century are often slightly thicker, wider, or cut with unique joinery that doesn’t align with contemporary production.

Only custom milled lumber can be matched to the original specifications. A mill shop can replicate exact widths, depths, and profiles, ensuring a replacement piece doesn’t look out of place or compromise the building’s historical authenticity.

2. Historic Properties Demand Architectural Accuracy

Preservation guidelines—especially in districts protected by local or national landmark commissions—often require that repairs and replacements remain faithful to original designs. Using mass-produced trim, stock crown molding, or factory windows can jeopardize approvals and reduce the value of the restoration.

By working with a craftsman experienced in historic replica wood products, property owners can be confident that every detail, from mortise-and-tenon joinery to decorative fluting, matches the original craftsmanship.

3. Many Historic Species Are No Longer Commercially Available

Centuries-old buildings often relied on wood species like heart pine, chestnut, or old-growth oak—species that aren’t commonly sold at today’s lumberyards. Custom milling allows artisans to work with reclaimed lumber or responsibly sourced alternatives that mimic the density, grain pattern, and durability of the originals. Accoya Acetelated wood is the only modern product bending the curve into better wood, as it is chemically altered to not absorb water!

For example:

Reclaimed heart pine beams can be remilled into flooring that matches Civil War–era homes.
Sapele or mahogany may be substituted for rot-resistant exterior trim when the original tropical hardwood is no longer available.
White oak can be quartersawn to mimic the shimmering ray fleck common in Arts & Crafts–era millwork.

The Process of Creating Custom Milled Lumber for Historic Replica Wood Products

Restoring or replicating historic woodwork is a precise and labor-intensive process. Unlike modern production lines that prioritize speed and uniformity, custom milling focuses on detail, flexibility, and one-of-a-kind accuracy.

Step 1: Site Assessment and Documentation

Architects and millworkers begin by surveying the property. Every molding, door stile, or window sash is measured, photographed, and cataloged. Shop drawings may be produced using AutoCAD or hand-drafted sketches. The goal is to capture the exact dimensions, joinery, and ornamental details.

Step 2: Lumber Selection

Choosing the right wood is critical. Preservationists balance authenticity with modern performance requirements. For exterior applications, rot resistance and stability may take precedence, while interior elements prioritize appearance and authenticity.

Step 3: Knife Grinding and Profile Matching

One of the hallmarks of custom milled lumber is profile replication. Specialized steel knives are ground to match the original profile of a molding or trim piece. This allows modern machinery to cut exact replicas that are indistinguishable from 150-year-old originals.

Step 4: Milling and Fabrication

Using planers, shapers, and moulders, raw lumber is transformed into historically accurate components. In some cases, hand tools are used to add the final detail or patina to match existing woodwork.

Step 5: Assembly and Joinery

For larger elements like historic replica windows and doors, traditional joinery methods—such as mortise-and-tenon or pegged joints—are reproduced. These not only provide structural strength but also honor the original methods of construction.

Step 6: Finishing

The final step includes sanding, staining, or painting. Some projects even call for custom finishing techniques to replicate the aged appearance of adjacent woodwork so that the replacement seamlessly integrates.

Applications of Custom Milled Lumber in Historic Replica Wood Products

1. Homes and Residential Properties

Private homeowners restoring historic residences often require custom millwork for:

Crown moldings and baseboards to match original interior detailing.
Custom windows and shutters designed with historically accurate joinery.
Staircases and banisters requiring hand-turned balusters or curved rails.
Doors and casings built with raised panels or specific architectural motifs.

2. Hotels and Hospitality Spaces

Grand hotels built during the Gilded Age or early 20th century often feature elaborate wood paneling, ballroom wainscoting, and carved ceiling beams. When these properties undergo restoration or adaptive reuse, custom milled lumber ensures that every lobby, guest room, and banquet hall reflects the elegance of its original era.

For boutique hotels in historic districts, the use of historic replica wood products also creates a sense of authenticity that appeals to guests seeking an immersive experience.

3. Mixed-Use Properties and Commercial Redevelopment

Across the country, developers are transforming warehouses, factories, and historic storefronts into mixed-use properties combining retail, office, and residential units. These adaptive reuse projects rely heavily on custom milled lumber to retain character while meeting modern code requirements.

Examples include:

Replicating storefront cornices for historic main streets.
Creating interior millwork that complements exposed brick and steel.
Designing historically accurate wood windows that meet energy efficiency standards.

Benefits of Using Custom Milled Lumber in Historic Replica Projects

Authenticity

Perhaps the greatest advantage is authenticity. Property owners avoid the “cookie-cutter” look of modern stock components, ensuring the finished project remains true to its origins.

Durability

Custom lumber can be milled from higher-quality, longer-lasting species, ensuring that restored woodwork stands the test of time.

Compliance with Preservation Standards

Local landmark commissions and preservation boards often demand accuracy. Using custom milled lumber demonstrates a commitment to historic integrity, increasing the likelihood of approval for renovation plans.

Increased Property Value

A historically accurate restoration not only preserves cultural heritage but also enhances market appeal. Buyers, investors, and tenants appreciate authentic craftsmanship that sets a property apart.

Sustainability

Reclaimed and responsibly sourced lumber used in custom milling reduces environmental impact while reusing materials that might otherwise go to waste.

Challenges in Producing Custom Milled Lumber

While the advantages are clear, producing custom milled lumber for historic replica wood products also involves unique challenges:

Cost: Custom milling requires specialized labor and tooling, which can be more expensive than off-the-shelf options.
Lead Times: Knife grinding, material sourcing, and fabrication extend project timelines.
Material Availability: Historic species may need substitutes that balance authenticity with availability.

However, most property owners find that the long-term benefits—authenticity, durability, and property value—far outweigh the initial investment.

Case Study Examples

Historic Hotel Renovation

A century-old hotel undergoing renovation required replication of 12-inch crown moldings and intricate ballroom paneling. Off-the-shelf products could not match the profiles. A mill shop used custom milled lumber with ground knives to create exact replicas, preserving the hotel’s grandeur.

Residential Restoration

A homeowner restoring an 1850s farmhouse needed historically accurate windows with true divided lights and hand-forged joinery. Custom milling provided sash frames that matched the originals while integrating energy-efficient glass.

Mixed-Use Development

Developers converting a tobacco warehouse into offices and apartments wanted to preserve the historic storefront façade. Custom milled lumber allowed replication of the original trim, pilasters, and transom frames, giving new life to the streetscape.

The Future of Custom Milled Lumber in Historic Replica Projects

As interest in historic preservation and adaptive reuse grows, the demand for custom milled lumber will continue to rise. Modern technology—such as CNC routers and 3D scanning—enhances accuracy, but traditional craftsmanship remains at the heart of the process.

Sustainability will also play a role. More projects are turning to reclaimed lumber, combining historical integrity with environmentally conscious practices.

For homes, hotels, and mixed-use properties alike, custom milled lumber remains the key to bridging the past and the present.

Conclusion

When it comes to preserving architectural heritage, there is no substitute for custom milled lumber. Whether the goal is restoring a historic home, renovating a grand hotel, or redeveloping a mixed-use property, authenticity and craftsmanship matter. Stock components cannot replicate the details, durability, or artistry of historic replica wood products.

By investing in custom milling, property owners ensure their projects meet preservation standards, stand the test of time, and honor the legacy of the structures they inhabit. From carved moldings to hand-crafted windows, custom milled lumber keeps history alive—one project at a time.

Bowed Windows Made in Virginia

by Gepetto Millworks | May 13, 2025 | Architectural Millwork, Wooden Windows

Round, Arc, Gothic Arch, and Bowed Windows Handcrafted in Virginia:

When it comes to bespoke architectural woodwork, Gepetto Millworks stands at the pinnacle of craftsmanship in Virginia. Specializing in historically accurate, handcrafted windows, our artisans are trusted by preservationists, architects, and homeowners alike. Among our most requested products are our round, arc, Gothic arch, and bowed windows—each style offering a unique aesthetic and functional value. Whether it’s the timeless elegance of a fully round window, the graceful curvature of an arc or bowed window, or the soaring lines of a Gothic arch, Gepetto Millworks captures the essence of historic Virginia architecture.

Round Windows: Architectural Focal Points Throughout the Centuries

Round windows have served as distinctive focal points in architecture throughout Virginia’s history. At Gepetto Millworks, our craftsmen meticulously re-create round windows to match the historic build style and quality ranging from small porthole-style accents to large oculi that dominate gable ends and facades in many prominant buildings. Fully round windows were especially popular during the Georgian and Federal periods as symbols of harmony and balance. The round, arc and elipsis windows appear above entryways or in pediments as focal features. In Victorian homes, especially in Queen Anne and Romanesque Revival styles, round windows added a touch of whimsy and light to stairwells, turrets, and attics.

If your historic Victorian home has a turret, the windows were likely crafted to fit, the exact outward arc to match the circumfrense of the turret. Gepetto’s craftsmen are specifically trained to reproduce the quality construction that has lasted a hundred years by using the highest quality sapele utilizing traditional mortise-and-tenon joinery true to the period. If you’re not familiar with Sapele it’s a similar wood to mahogony which comes from Africa, instead of South America. Sapele lumber is a hardwood sourced from the Entandrophragma cylindricum tree, native to Africa. It’s often used as a substitute for mahogany, especially South American mahogany, due to its similar appearance and properties. Sapele is known for its rich reddish-brown color, which can darken with age, and its natural luster. The grain can be interlocked, creating beautiful figures like ribbon, quilted, and pommele. Most important for windows, Sapele and Mahogany are used as they machine very straight, and have a high resistance to rot from absorbed water. The new choice for stabilized and rot resistant wood stock is called Accoya – read about the treatment of Acetylation for wood.

Arc Windows: Graceful Curves for Historic Spaces

Arc windows feature a curved top with straight sides. Often featured in church buildings, estate homes, and public structures across Virginia, arc windows bring an understated elegance like a flower at the top of a stem. In historic Virginia architecture, arc windows made their appearance during the late Federal and early Victorian periods as craftsmen were called on to fabricate the more elaborate designs of architects. Especially prevalent in Southern plantation homes, often installed above doors, you’re subtly familiar with their placement but as you start to google for a contractor to repair or replace them, you’ll find that it’s nearly a lost art! Not to worry, Gepetto’s staff are trained and experienced in the mathematical proportions, and the tooling needed to producing these complex shapes to exactly match your historic window. At Gepetto Millworks, our arc windows are handcrafted to match. We replicate traditional molding profiles, sash styles, and muntin patterns while integrating modern glazing technology.

Gothic Arch Windows: A Testament to Virginia’s Ecclesiastical and Romantic Heritage

Gothic arch windows are instantly recognizable by their pointed arches and narrow vertical proportions. Found in churches, academic buildings, and large estates, these windows are emblematic of the Gothic Revival movement. The Gothic Revival architectural movement in the United States swept into Virginia, occurred in the building furvor from approximately 1840 to 1880. Crafting a Gothic arch window requires immense skill and precision. Gepetto Millworks artisans sculpt each piece from premium hardwood, ensuring the pointed apex is structurally sound and visually perfect. These windows often feature intricate tracery and divided lights, requiring a high degree of technical craftsmanship that the shop at Gepetto keeps alive. Our Gothic arch windows grace both restorations of Virginia’s historic churches and modern homes that seek to incorporate classical drama. Whether you are restoring a cathedral in Richmond or adding a Gothic-inspired touch to a custom estate in Charlottesville, Gepetto’s windows are your go-to source.

Bowed Windows: The Victorian Love Affair with Curves

Bowed windows curve outward from a building’s facade, often found in Victorian homes, especially those with turrets and bay extensions. In Virginia, these outwardly bowed windows became especially fashionable during the mid to late 1800s as urban and rural homeowners sought to display their wealth and architectural savvy through the new homes they were building with the most intricate or ornate results. Bowed windows require a mastery of compound curves and precision framing. Gepetto Millworks brings over three decades of experience crafting bowed windows that seamlessly fit into historic turret structures in wood or stone. Our team works closely with architects and homeowners to ensure the curvature and mullion spacing complements the building’s scale and period for an exact match.

Each bowed window is assembled by hand using traditional joinery methods and features high-performance glazing for durability and energy efficiency. Our craftsmen have recreated bowed windows for homes in Alexandria, Norfolk, and Staunton—preserving the distinctive Victorian charm of their turrets and facades.

Federal Period Elipsis Overlights: A Distinctive Accent of Historic Virginia

Elliptical overlights—also known as fanlights—were a hallmark of the Federal period, providing natural light and architectural refinement above entry doors. In Virginia, these elipsis-shaped windows were often adorned with intricate muntin patterns and flanked by sidelights. Gepetto Millworks specializes in accurately recreating these elliptical overlights using historical blueprints, archival photos, or surviving fragments. Our reproductions have graced the doorways of plantation homes in Williamsburg, townhouses in Fredericksburg, and government buildings in Richmond. Using custom bending forms and precision-cut jigs, our artisans handcraft each elliptical frame, fitting it with period-correct glazing and mullion patterns. We also offer restoration services for damaged or incomplete overlights, ensuring these iconic features endure for future generations.

What sets Gepetto Millworks apart in Virginia’s landscape of historic window craftsmen is our relentless attention to detail and commitment to authenticity. Every round, arc, Gothic arch, and bowed window is a testament to our passion for historical accuracy and our dedication to artisanal woodworking. We collaborate with historical societies, preservation commissions, and homeowners who want their architectural features to reflect the period styles of Virginia’s diverse architectural heritage. From the coastal Georgian mansions of the Tidewater region to the highland estates of the Shenandoah Valley, Gepetto Millworks is proud to be the trusted name for period-specific window design and fabrication.

Our craftsmen utilize time-honored techniques:

Mortise-and-tenon joinery
Hand-carved moldings
Custom-milled sash profiles
Historically accurate glass lites and muntins
Fine finishing using natural oils and historically accurate paint
Each window is more than a product; it is a legacy piece that honors the architectural lineage of Virginia.

Monticello Region: In Charlottesville, a late-Federal style estate required a full set of elliptical overlights and arc windows. Gepetto Millworks used historic blueprints and archival photos to reconstruct each window, earning praise from the local historical society.

Downtown Richmond: A restored Gothic Revival church needed over a dozen custom Gothic arch windows, including tracery patterns unique to the building. Our craftsmen worked on-site to ensure a seamless fit and aesthetic harmony.

Norfolk Victorian Mansion: This turreted Victorian home received a full bowed window rebuild, fabricated in our workshop and installed with precision to preserve its dramatic street-facing curve.

Fredericksburg Federal Home: Damaged elliptical overlights were restored to their former glory, complete with fan muntins and clear restoration glass.

Architectural Continuity and Innovation

While our windows reflect historic aesthetics, they also meet modern performance standards. All Gepetto Millworks products are available with insulated glazing units, low-E glass, and weather-sealing. We believe that preserving Virginia’s architectural history should not come at the cost of energy efficiency. Our design team works in AutoCAD and Revit for precision planning, and we offer full shop drawings for complete sizing, fit, and approval for client visualization. Blending of old-world craft and modern technology makes Gepetto Millworks a leader in both restoration and new construction projects. From conceptual design through installation, Gepetto Millworks offers a collaborative and professional approach. Our window specialists consult on site-specific challenges, whether it’s ensuring a bowed window maintains the correct radius or replicating a Gothic arch to meet preservation board standards.

We welcome:

Homeowners restoring historic properties
Architects designing period-sensitive new builds
Contractors managing adaptive reuse projects
Preservationists requiring documentation and authenticity

Craftsmanship Rooted in Virginia History

Round, arc, Gothic arch, and bowed windows have each played a defining role in Virginia’s architectural evolution. At Gepetto Millworks, we honor that legacy with handcrafted windows built to exacting standards. Whether you’re restoring a Federal period home with elliptical overlights, adding a bowed window to a turreted Victorian, or installing a fully round window as a dramatic focal point, our team are Virginia natives that live in and pass by the history that has made us each day. Call Matt direct at 804.938.2097 to schedule your project into the pipeline. Reach out today to bring historical accuracy and artisanal detail to your project.

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VCU SCOTT HOUSE Window Restoration

by Gepetto Millworks | Jun 9, 2024 | Architectural Millwork, Historic Restoration, Project Spotlight, Virginia, Wooden Windows

SCOTT House on VCU Campus

Window Restoration

Beaux Arts style Window Restoration

Authentic Craftsmanship

THE SCOTT HOUSE is one of Richmond’s most significant examples of American Renaissance architecture and is listed on the National Register of Historic Places. It was completed in 1911 and acquired by Virginia Commonwealth University (VCU) in 2001. The 18,000 sf mansion was built for Frederic William Scott and his wife Elizabeth Strother Scott. It was modeled after the Marble House in Newport, Rhode Island, which referenced the Petit Trianon at Versailles. Interior plasterwork is attributed to prominent sculptor and plaster contractor, Ferruccio Legnaioli.

VCU commissioned Glavé & Holmes Architecture (G&H) to provide a feasibility study to assess existing conditions, programming, and conceptual design. Subsequently, G&H was selected to provide a historically-sensitive rehabilitation to allow the building to serve as meeting and event space for visiting and University groups.

Goals for rehabilitation the Scott House included restoration of the exterior masonry and windows supplied by Gepetto Millworks Mechanical, electrical and plumbing systems were upgraded to modern standards. New restrooms, and conversions to office space and meeting rooms became part of the plans to serve the University Campus. While the rehabilitation will serve a variety of modern programmatic functions, the building’s historic fabric was restored in accordance with the Secretary of the Interior’s Standards for Rehabilitation and the University’s preservation philosophy for historic buildings.

Historic preservation seeks to find effective and artful ways of maintaining and reusing significant buildings, landscapes, and communities. Central to the discipline is the attempt to preserve cultural identity in the face of the threats of urban sprawl and loss of social diversity.

Maintain, protect, and repair authentic character defining features, materials, and finishes. If features are deteriorated beyond repair, replace them in-kind. Retain authentic historic building fabric to the maximum extent possible.

Historic building restoration respects the evolution of historic changes, fashion, taste, and use – do not try to “improve” the design of authentic building features.

Avoid installation of conjectural “historic” features.

Do not use maintenance methods or materials that damage significant building and landscape fabric.

Authentic Window Restoration Richmond

Richmond VA Authentic Historic Window Restoration

Scott House was built in 1907, and is a three-story, 40,950 square foot, Beaux Arts style mansion. The house is seven bays wide and is faced with a pale Indiana limestone. It features a central portico of four, giant Corinthian order columns and two Corinthian pilasters that dominate the highly formal, symmetrical entrance façade. Elizabeth and Frederic Scott bought the property from Lewis Ginter in 1903, Elisabeth Scott Bocock, moved into the house in the mid 20th century. While there, she founded the Historic Richmond Foundation, the 2300 Club, and the Hand Workshop (now known as the Visual Arts Center of Richmond). In the 1960s, the house was subdivided and used as dorms for VCU students, which continued into the 90s. A renovation in 2004 led to the Scott House opening its doors to the public, and the designation of the building as a Virginia Historic Landmark.

The historic Marble House in Newport, Rhode Island was chosen as inspiration for the Richmond structure, which was itself modeled after the Petit Trianon in Versailles. It stands proudly removed from West Franklin, an exception to the block’s density. The stately house, a handsome combination of limestone and terra cotta, is grounded by green-tiled wrapping terraces and a porte-cochére, shaded by trees in the house’s garden. Oxidized copper and careful cast iron work beautifully balance the gravity of the building’s exterior. Oversized fluted columns with Corinthian capitals give the mansion a sense of monumentality. The interior is a classic example of the American Renaissance style, originating in the 18th century. The occupant moves through the symmetrically divided rooms with no hallways on the first floor, structured around a main entrance stair which lies under a magnificent stained glass dome. Servants’ quarters are to the rear of the building, and a large English style carriage house is hidden behind the mansion. The Anderson Gallery, constructed in 1888 from the former Ginter House stables, also stands behind the Scott-Bocock House. The splendor of the structure is a reminder of Richmond’s insurance and banking glory days in the early 20th century, when it was an indulgent capital of the South.

Authentic Historic Window Restoration Virginia