Virginia Federal Period Doors & Millwork

The Federal Period, spanning from the late 18th to the early 19th century, was a crucial era in American architecture that saw the emergence of distinct design elements and principles. In Virginia, during this period, homes became symbols of refined taste and elegance, reflecting the influence of Neoclassical ideals. One of the key architectural features that encapsulates the essence of Federal style homes in Virginia is the front door entryway.

The front door entryway of a Federal period home in Virginia was meticulously designed to embody the principles of balance, symmetry, and classical motifs. Elliptical fanlights and sidelights were popular components of these entryways, contributing to the overall aesthetic appeal. The use of ellipses in the windows was not merely decorative but also served a functional purpose by allowing an abundance of natural light to flood the entrance hall.

Windows spanning two sidelights became a distinctive hallmark of Federal style architecture in Virginia. The arrangement of these elements was carefully orchestrated to achieve visual harmony. The elliptical fanlight positioned above the door, along with the sidelights on either side, created a balanced and symmetrical composition. This adherence to symmetry was influenced by Neoclassical principles, which sought inspiration from classical Greek and Roman architecture.

The choice of elliptical windows was not arbitrary; it was rooted in the classical language of architecture. The ellipse, with its graceful curves, echoed the elliptical arches prevalent in ancient Roman structures. This classical reference was a deliberate attempt to evoke a sense of timelessness and cultural continuity. The use of classical motifs was a defining characteristic of Federal style architecture, as it sought to establish a connection with the ideals of ancient civilizations.

As we delve into the specifics of these front door entryways, it’s essential to acknowledge the craftsmanship that brought these designs to life. Gepetto Millworks, situated in the picturesque Blue Ridge Mountains, played a pivotal role in manufacturing the intricate components of Federal period homes in Virginia. The artisans at Gepetto Millworks were adept at translating architectural drawings into finely crafted wooden elements, bringing authenticity and precision to each piece.

Gepetto Millworks embraced the architectural principles of the Federal period, ensuring that their creations adhered to the standards of balance and proportion. The ellipses in the windows were meticulously carved, and the sidelights were crafted with precision to complement the overall symmetry of the entryway. The choice of materials, often hardwoods like mahogany or cherry, added a touch of luxury to these architectural elements.

The Blue Ridge Mountains, with their natural beauty and serene landscapes, provided an inspiring backdrop for the artisans at Gepetto Millworks. Surrounded by such scenic vistas, the craftsmen found motivation to infuse a sense of craftsmanship and artistry into each piece they produced. This connection to nature and the local environment contributed to the unique character of the architectural elements manufactured by Gepetto Millworks.

Federal Period Doors & Millwork Produced Locally in Virginia

The Federal period in Virginia was marked by a departure from the ornate styles of the preceding Georgian era. Federal architecture embraced simplicity, symmetry, and a reliance on classical motifs. The front door entryways, with their elliptical fanlights and sidelights, epitomized these principles. The ellipses in the windows, while serving a functional purpose, also added a touch of grace and sophistication to the overall design.

Symmetry was a fundamental aspect of Federal architecture, and the front door entryway was no exception. The placement of the elliptical fanlight at the center, flanked by two sidelights, created a balanced and harmonious facade. This commitment to balance was not only an aesthetic choice but also a reflection of the intellectual currents of the time, which valued order and proportion.

The classical motifs found in Federal architecture were a deliberate homage to the ideals of ancient Greece and Rome. The architects and craftsmen of this period sought to evoke a sense of timelessness by drawing inspiration from the classical past. The use of ellipses in the windows, reminiscent of Roman arches, was a clear nod to the enduring legacy of classical architecture.

Gepetto Millworks, nestled in the Blue Ridge Mountains, embraced these principles in their manufacturing process. The artisans at Gepetto understand the importance of precision and attention to detail in creating authentic Federal period architectural elements. The choice of materials, combined with skilled craftsmanship, resulted in front door entryways that not only adhered to the architectural principles of the time but also showcased the natural beauty of the wood.  In the federal period we see the impact of the deployment of machine labor to wood allowing for the explosion in trim and styling of some of the ornate libraries, entry halls, staircases and the ever present focal point of the front door.

In addition to the visual appeal, the front door entryways of Federal period homes in Virginia also served a functional purpose. The elliptical fanlights above the doors allowed ample natural light to enter the entrance hall, creating a welcoming and well-lit space. This consideration of both form and function reflected the pragmatic yet elegant sensibilities of Federal architecture.

As we admire these front door entryways, it’s worth noting that Federal style architecture in Virginia was not confined to grand mansions. The principles of balance, symmetry, and classical motifs permeated homes of various sizes and scales. Whether in urban townhouses or rural estates, the front door entryway became a focal point, signaling the taste and sophistication of the inhabitants.

The front door entryways of Federal period homes in Virginia stand as enduring examples of architectural excellence. The ellipses in the windows, spanning two sidelights, showcase a commitment to classical principles of balance and symmetry. Manufactured by Gepetto Millworks in the Blue Ridge Mountains, these architectural elements embody a harmonious blend of craftsmanship, natural beauty, and a deep appreciation for the Neoclassical ideals of the Federal period. As we continue to study and celebrate the architectural legacy of this era, the front door entryways remain iconic symbols of a bygone time, preserving the elegance and grace of Federal style architecture in Virginia.

The elliptical fanlight, positioned above the front door, is a key feature that distinguishes Federal period homes in Virginia. This design choice goes beyond mere aesthetics, as the ellipse itself is a shape laden with historical and cultural connotations. Inspired by the elliptical arches of ancient Roman architecture, the use of ellipses in the windows pays homage to classical ideals. It serves as a visual link to the timelessness of classical civilizations, emphasizing a connection to the intellectual and cultural heritage of the past.

The elliptical fanlight also plays a crucial role in welcoming natural light into the entrance hall. This functional aspect aligns with the practical sensibilities of the Federal period. The desire for well-lit interiors was not only an aesthetic preference but also a manifestation of the period’s interest in creating inviting and hospitable spaces. The soft, diffused light streaming through the elliptical fanlight contributes to the overall ambiance of the entryway, making it a warm and inviting focal point.

Complementing the elliptical fanlight are the two sidelights positioned on either side of the front door. This symmetrical arrangement enhances the visual balance of the entryway, a hallmark of Federal architecture. The sidelights serve both practical and aesthetic purposes. They allow additional light to enter the interior, further illuminating the entrance hall and creating a sense of openness. Moreover, the sidelights contribute to the grandeur of the facade, framing the entrance in a way that accentuates its significance.

The combination of the elliptical fanlight and the two sidelights creates a harmonious trio, each element enhancing the other’s impact. The ellipse, with its graceful curves, contrasts with the vertical lines of the sidelights, creating a dynamic visual interplay. This contrast adds a layer of complexity to the design, elevating it beyond a mere exercise in symmetry. The play of light and shadow on the intricate detailing of the fanlight and sidelights enhances the depth and richness of the overall composition.

Beyond their aesthetic appeal, these architectural elements convey a narrative of cultural refinement and intellectual sophistication. The use of classical motifs, such as the elliptical arch, suggests a deliberate engagement with the philosophical and artistic ideals of antiquity. The Federal period was a time of intellectual curiosity and a desire to establish a distinct American identity that drew inspiration from the classical world. The front door entryway, with its unique combination of elements, became a canvas for expressing these ideals.

Gepetto Millworks, situated in the Blue Ridge Mountains, played a crucial role in bringing these unique design elements to life. The craftsmen at Gepetto understood the significance of the elliptical fanlight and sidelights in Federal period architecture. Their meticulous attention to detail and commitment to traditional craftsmanship ensured that each piece produced reflected the authenticity and elegance of the era.

In conclusion, the combination of the elliptical fanlight above the front door and the two sidelights flanking it represents a distinctive and iconic feature of Federal period homes in Virginia. This architectural ensemble goes beyond its visual appeal; it embodies the intellectual aspirations of the time, drawing inspiration from classical traditions. The play of light, the balance of forms, and the craftsmanship involved in creating these elements contribute to the enduring legacy of Federal style architecture. As we appreciate these front door entryways, we not only glimpse into a specific historical period but also witness the timeless beauty of design principles that continue to shape the look & flavor of our great Virginia Cities from Norfolk, Alexandria, to Charlottesville and Richmond.

federal style doors made to order virginia
federal style doors made to order virginia
federal style doors made to order virginia
federal style doors made to order virginia
federal style doors made to order virginia
federal style doors made to order virginia
federal style doors made to order virginia
federal style doors made to order virginia
Rustic Aesthetic REal wood Manufacturer

Rustic Aesthetic REal wood Manufacturer

Rustic, Country Chic, and farmhouse style aesthetics have gained immense popularity with interior design across Virginia, West Virginia, North & South Carolina the core service areas Gepetto delivers custom wood built millwork within. The appeal boils down to offering a cozyness, the appeal of exposed wood grain has an attraction buried deep within the human psyche. A design theme centered around wood that evokes a sense of warmth, simplicity, and a connection to nature makes the perfect customer for Gepetto.

We apply the same warm blend of historic styles to modern homes, restaurants and office spaces as well if you are a design architect reading this we look forward to getting you on the phone before you start your surface design specifications so that we can talk about species, placement and cost saving measures we can achieve for you. The rustic styles create inviting environments that prioritize human comfort and well-being. Gepetto Millworks fabricates and delivers conference room tables or wooden desk surfaces that feel warm and look touchable. Based in the hills near Charlottesville, Virginia, we have done many projects sourcing directly from Virginia barn structures that are falling apart repurposing them into. We bring the rustic design elements to life through custom fabricating furnishings, infusing spaces with character and charm that we tore down from other spots in Virginia.

Rustic Charm in Restaurant Furnishings

Rustic design is characterized by its use of natural materials, earthy tones, and a focus on simplicity. In restaurant furnishings, this aesthetic can be translated into wooden tables, chairs, and reclaimed materials that give the space a warm and inviting ambiance. Gepetto Millworks, with its expertise in custom woodworking, can craft unique pieces that showcase the beauty of natural wood grains and textures. And in today’s era, we have to state that these are all solid wood – no facings, veneers or other shortcuts that don’t wear well or last.

Consider a restaurant with a farmhouse-inspired theme, where the tables are crafted from reclaimed barn wood, complete with the imperfections and history of the material. The chairs might feature woven seats or distressed finishes, adding to the rustic appeal. Gepetto Millworks can create custom booths with plush, upholstered seating in earthy tones, enhancing the comfort and coziness of the dining experience.

Additionally, incorporating open shelving made from reclaimed wood for displaying dishes or rustic lighting fixtures can further enhance the overall aesthetic. The goal is to create an atmosphere that feels welcoming and authentic, encouraging patrons to relax and enjoy their dining experience.
Embracing Country Chic in Office Spaces

Country Chic design brings together elements of vintage charm and contemporary style. When applied to office spaces, it can transform work environments into comfortable and visually appealing places. Gepetto Millworks can play a pivotal role in achieving this by crafting bespoke office furniture that combines functionality with aesthetic appeal.

Imagine an office reception area with a distressed wooden desk, adorned with vintage accessories and accents. The use of pastel colors and floral patterns in upholstery can contribute to the Country Chic vibe. Gepetto Millworks can design and build custom storage solutions such as bookshelves or cabinets, incorporating beadboard paneling or other country-style details.

For workstations, the use of reclaimed wood for desks and ergonomic chairs upholstered in soft, natural fabrics can create a workspace that is both comfortable and visually pleasing. Country Chic office spaces can benefit from the integration of potted plants, artwork, and decorative items that evoke a sense of hominess.

Farmhouse Aesthetics: A Blend of Comfort and Functionality

Farmhouse aesthetics often focus on the fusion of comfort and functionality with a not to Virginia’s historic past. Our commitment to craftsmanship can bring this fusion to life in both restaurant and office settings. In restaurant furnishings, farmhouse-inspired tables with sturdy construction can withstand the rigors of daily use while maintaining a charming appearance.

Farmhouse-style seating with cushioned benches and wooden chairs can contribute to a convivial atmosphere. Gepetto Millworks can customize these pieces to align with the specific needs and preferences of the establishment, ensuring that both the staff and patrons enjoy the space.

In office settings, farmhouse aesthetics can be integrated into conference rooms, creating a collaborative and inviting space. Large, robust tables made from solid wood can serve as a focal point, complemented by comfortable seating. Gepetto Millworks can incorporate storage solutions that seamlessly blend with the farmhouse theme, providing practicality without sacrificing style.

Gepetto Millworks: Crafting Unique and Personalized Spaces

Gepetto Millworks, based in Richmond, Virginia, is uniquely positioned to bring the charm of Rustic, Country Chic, and farmhouse aesthetics to life. The company’s commitment to craftsmanship and customization ensures that each piece of furniture is not just functional but also a work of art.

The artisans at Gepetto Millworks have a keen understanding of design principles and can work closely with clients to capture the essence of the desired aesthetic. Whether it’s creating a cozy dining nook for a restaurant or designing a welcoming office lobby, Gepetto Millworks excels in translating visions into tangible, high-quality furnishings.
Conclusion: Elevating Spaces with Timeless Design

In conclusion, Rustic, Country Chic, and farmhouse aesthetics offer a wealth of design potential for restaurant and office spaces, focusing on human comfort and warm elements. Gepetto Millworks, situated in Richmond, Virginia, stands out as a reliable partner in bringing these design themes to life through custom furnishings.

By harnessing the beauty of natural materials, expert craftsmanship, and a commitment to personalized service, Gepetto Millworks can transform spaces into havens of comfort and style. Whether it’s the rugged charm of Rustic design, the vintage allure of Country Chic, or the functional elegance of farmhouse aesthetics, Gepetto Millworks has the expertise to craft furnishings that resonate with the unique identity of each establishment.

circular architectural wood elements turned on a lathe

circular architectural wood elements turned on a lathe


The art of turning wood on a lathe to create circular architectural elements is a blend of tradition, craftsmanship, and aesthetic vision. This practice, integral to woodworking and architecture, has evolved over centuries, adapting to changing styles and technological advancements while maintaining its core principles of shaping wood into functional and decorative forms.

Historical Significance

Woodturning, the process of shaping wood while it is rotated on a lathe, has been a fundamental woodworking technique since ancient times. The lathe, one of the oldest woodworking tools, is believed to have originated in ancient Egypt. Over the centuries, it has played a crucial role in the development of architecture, particularly in the creation of circular wood elements. These elements have not only provided structural support but have also been central to decorative motifs in various architectural styles.

Types of Circular Architectural Elements

    1. Balusters: These are the vertical supports in a balustrade system, commonly seen on staircases and balconies. Each baluster is turned to achieve a specific design, which can range from simple cylindrical shapes to more complex, intricate patterns.

    1. Newel Posts: Serving as the anchor points of a staircase railing system, newel posts are often more substantial and elaborately designed than balusters. They mark the beginning, end, and turns of staircases.

    1. Columns and Pilasters: These are fundamental in classical architecture, providing both support and ornamentation. Turned wooden columns often mimic the styles of their stone counterparts, such as Doric, Ionic, and Corinthian designs.

    1. Finials: Decorative end pieces that can be found on top of newel posts, bed posts, curtain rods, and other architectural features. Finials range from simple rounded shapes to complex, carved designs.

The Turning Process

The process of turning wood on a lathe requires skill and precision. A craftsman selects a suitable piece of wood, considering factors like grain, texture, and strength. The wood is then mounted on the lathe, which rotates it at high speeds. Using various chisels and gouges, the woodturner shapes the wood, carefully following the design specifications.

The creation of circular architectural elements is not just about removing excess wood; it’s about understanding the material’s properties and working with them to achieve a balance between strength and beauty. The woodturner must consider the final application of the piece, ensuring that it is not only aesthetically pleasing but also structurally sound.

Applications in Architecture

Circular wood elements turned on a lathe find their application in various architectural contexts:

    • In residential architecture, they add elegance and character to staircases, porches, and furniture.

    • In public and historical buildings, they often play a role in preserving the architectural integrity and aesthetic of the structure.

    • In modern architecture, while the styles may have evolved, the fundamental process of turning wood for circular elements remains a testament to traditional craftsmanship.

Artistry and Craftsmanship

The creation of these elements is as much an art as it is a craft. The woodturner must have an eye for detail, an understanding of architectural styles, and the ability to translate a design concept into a tangible wooden form. This process requires not only technical skill but also a deep appreciation for the material and the history it carries.

Technological Advancements

While the basic principles of woodturning have remained constant, technological advancements have introduced new tools and techniques, allowing for greater precision and efficiency. Today’s woodturners can achieve more complex designs and consistent results, but the essence of the craft — the connection between the material, the tool, and the craftsman — remains unchanged.

Sustainability and Material Choice

In contemporary practice, there is an increasing focus on sustainability. The choice of wood, its sourcing, and the impact of the manufacturing process on the environment are important considerations. Woodturners and architects often opt for locally sourced, renewable wood species, ensuring that their creations are not only beautiful but also environmentally responsible.

Cultural Significance

Circular architectural elements turned on a lathe are not just functional components of a structure; they are bearers of cultural and historical significance. They reflect the architectural trends of their time, the skill of the craftsmen, and the cultural context in which they were created.

In conclusion, the practice of turning wood on a lathe to create circular architectural elements is a fascinating blend of history, art, and craftsmanship. It highlights the enduring relationship between humans and their environment, where a simple piece of wood, through the skilled hands of a craftsman, is transformed into a piece of architectural beauty. This tradition, rooted in the past, continues to evolve, adapting to modern needs while preserving the essence of the craft.

Matthew Wiley wood turning supplier
@gepetto.millworks The original bed finials at the Omni Homestead resort were misplaced during the extensive renovation process. As months went by, these finials became the final missing component, causing a delay in completing the project. Today, we are delighted to announce the successful delivery of 60 handcrafted and stained finials, which required only one week of shop time. This accomplishment marks the end of a four-month search! If you are in need of wooden historic replacement parts, your first step should be reaching out to Gepetto. You can contact Matt at ‪(804) 938-2094 to tap into 30 years of construction knowledge and expertise. Matt can provide you with an accurate project timeline that Gepetto will commit to delivering on time as agreed upon. #historicreplica #woodturning ♬ original sound - Gepettomillworks
made to order custom round wooden turned millwork
circular architectural wood elements turned on a lathe
bulk orders for historic replica millwork
Turning Service for Bulk Orders

Turning Service for Bulk Orders

Gepetto Millworks, based in the blue ridge mountains of Virginia has established a strong reputation over the past three decades for custom manufacturing wood projects. Their expertise spans a wide range of woodwork, from building or restoring any wooden item to tackling complex and intricate challenges in the building industry. This versatility is showcased in projects like creating three-story hanging spiral staircases, bar tops, historic stained glass restoration, and modern office interiors.

Key to Gepetto’s success is the leadership of Matthew Wiley, who brings over 30 years of experience in renovating and restoring historic homes, warehouses, and churches in Richmond. His transition from building individual windows and doors to managing a production facility enables Gepetto to handle any project demand, large or small. Wiley’s collaboration with architects, project managers, and developers is particularly noted for gaining tax advantages through the use of historically accurate wooden building materials in large scale commercial projects.

One of Gepetto’s specialties lies in historic renovations. They are adept at crafting new solid wood windows, doors, trim, skylights, railings, and newel posts, even from the most damaged or unsalvageable pieces, to match the original designs. This meticulous attention to detail ensures that buildings maintain their historic essence, making them eligible for building tax credits.

A unique service offered by Gepetto is the hand-turning of solid wood rounds for historic restoration projects. They recreate damaged or worn parts in their Charlottesville, VA shop, emphasizing the custom, handmade nature of their work, which is a critical aspect of their business approach.

Meeting the needs of customers for turned wood products in the round that provide handmade millwork for one-off orders up to thousands of pieces, Gepetto Millworks demonstrates a commitment to quality, customization, and preservation of historical integrity in woodworking. Their capacity to handle diverse and complex projects, combined with their craftsmanship and expertise in historic restoration, positions them uniquely to cater to a wide range of customer needs in the field of custom woodwork.

Hand Turned Historic Replica Supplier

 

Historic Replica Wood TUrning

Historic Replica Wood TUrning

Solid Wood - Hand Turned

As the lathe begins to spin, the world outside fades away. There’s only the wood and me, connected in a dance as old as time. The whirring sound of the lathe blends with the distant calls of birds, creating a symphony that guides my movements. My hands, guided by years of experience, move with a precision that feels almost instinctual, shaping the wood, releasing its hidden beauty.

Historic Replica Wood Turnings

As I step into my workshop, nestled in the shadows of the Blue Ridge Mountains just outside Charlottesville, the familiar scents of the fresh growing woods outside and dried wood shavings inside fills my senses. I am instantly grounded to the present moment and my carpenter ancestors. The lathe, my tool for this artistic journey, stands ready, a invitation to spin up the music of the day’s meditation.

Selecting a piece of wood is a ritual in itself. Each piece, unique in its grain and texture, speaks of the history of the mountains, of rains and suns it has witnessed. Today, I choose a piece of african mahogany, its rich, reddened warm tones resonating with the early morning light filtering through the windows.  A sip of coffee while watching the turkey’s dry the dew from their feathers feels so right to my Virginia Hillbilly roots

Made To Order from Virginia

As the lathe begins to spin, the world outside fades away. Only the wood speaks to me, connected to the immediate danger of a tool that will take my finger in an instant. The whirring sound of the lathe blends with my breath creating a focused symphony of precision movements. My hands, guided by years of experience, move that precision up and down feeling almost instinctual, shaping the wood to the exact pattern.

Turning wood on a lathe is more than a craft; it’s a form of meditation that if you rush will ruin many a piece of stock. Each curl of wood that spirals away is a reminder of the impermanence of life, of the constant cycle of creation and transformation. The wood’s resistance and surrender under the tools mirror the ebb and flow of thoughts in my mind, allowing me to reach a state of Zen-like focus.

Virginia Historic Replica Turnings

The mountains, visible through my workshop’s open door, stand as silent witnesses supporting this meditative practice. I am tuned in to the enduring nature of our existence and my grandfather’s who raised the barns and decorated the homes of Virginia for the last few hundred years. The quality of the materials I work with, each piece a fragment of a former project being reused imbues my creations with a soul, a story. The intricate connection we grow from the world around us.

There’s a rhythm in turning wood, a harmony that aligns with the natural rhythms of the earth. The mountains, with their changing colors and moods, are a constant source of inspiration and backdrop to our shop. They remind me that just like the wood that takes new shapes under my hands, we too are capable of transformation and growth.

Turned Wood Made to Order

Hours pass without notice, as the stack of finished pieces grow behind me. The piece on the lathe slowly takes form, evolving from a rough block into a fitted form. The satisfaction of creating something beautiful, functional, and lasting is profound. It’s a connection not just to the material, but to the tradition of craftsmanship, to the history embedded in the wood, and to the serene beauty of the mountains that encompass my workshop.

As the day comes to an end, and the lathe falls silent, I step back to admire the finished pieces. In its curves and smoothness, I see not just my work, but the journey of the wood, from the heart of the mountains to the heart of someone’s home. This connection, this cycle of life and art, is the essence of my daily meditation, a reminder of the beauty and interconnectedness of all things.

bulk order turned wood pieces for historic matching

historically accurate architectural details made to order

bulk order turned wood pieces for historic matching

circular architectural wood elements turned on a lathe

bulk order turned wood pieces for historic matching

@gepetto.millworks The original bed finials at the Omni Homestead resort were misplaced during the extensive renovation process. As months went by, these finials became the final missing component, causing a delay in completing the project. Today, we are delighted to announce the successful delivery of 60 handcrafted and stained finials, which required only one week of shop time. This accomplishment marks the end of a four-month search! If you are in need of wooden historic replacement parts, your first step should be reaching out to Gepetto. You can contact Matt at ‪(804) 938-2094 to tap into 30 years of construction knowledge and expertise. Matt can provide you with an accurate project timeline that Gepetto will commit to delivering on time as agreed upon. #historicreplica #woodturning ♬ original sound - Gepettomillworks
@gepetto.millworks Matt is making #handturned column bases from solid mahogany today in the shop - if you don’t think that you can find the parts and pieces for your #historicrenovation ♬ original sound - Gepettomillworks

Enjoy some music with us while you browse our site!

Decorative architectural elements that are round and typically require turning on a wood lathe include:

  1. Balusters: Vertical members in a railing system, often found in staircases and balconies.
  2. Newel Posts: Larger, more decorative posts at the bottom or top of staircases.
  3. Finials: Decorative, often pointed elements that cap posts, furniture, or architectural features.
  4. Columns and Pilasters: Round, often tapered, structural elements supporting roofs or arches.
  5. Rosettes: Circular, ornate decorative pieces, often used around doorknobs or in ceiling decor.
  6. Spindles: Smaller turned pieces used in furniture or as decorative accents.
  7. Handrails: Part of a staircase or balcony railing, turned for decorative effect.
  8. Table Legs: Often turned for aesthetic appeal in various styles.
  9. Chair Legs and Backs: Round elements in chairs are commonly created using a lathe.
  10. Cabinet Knobs and Pulls: Round or oval knobs and handles for drawers and cabinets.
  11. Dowels: Used in various applications, from curtain rods to structural supports.
  12. Corbels: Ornate, curved supports for shelves, mantels, or other overhangs.
  13. Bun Feet: Rounded feet often used for furniture like sofas, armchairs, or cabinets.
  14. Crown Molding Corners: Curved pieces where crown molding meets in corners.
  15. Decorative Appliques: Various round, carved pieces added for embellishment.

Beautiful Turned Wood Promotional Items

If you are not having us turn architectural decorative elements for historic restoration building projects – you might have us make custom promotional items like:

  1. Tool handles
  2. Lidded boxes
  3. Jewelry boxes
  4. Round jewelry holders
  5. Wooden cups/mugs
  6. Wooden cell phone holders
  7. Luxury desk sets
  8. Wooden wheels
  9. Wooden gears
  10. Wooden game pieces

Contact Matthew For Custom Wood Turning

Timeline

Matthew Wiley wood turning supplier

Matthew Wiley wood turning supplier

circular architectural wood elements turned on a lathe

circular architectural wood elements turned on a lathe

made to order custom round wooden turned millwork

made to order custom round wooden turned millwork

turning wood craftsman making multiple newells to order

turning wood craftsman making multiple newells to order

circular architectural wood elements turned on a lathe

circular architectural wood elements turned on a lathe

wood turning shop virginia custom order supplier

historic replica unique one off wood decorative element building materials

Clerestory restoration parts and service

Clerestory restoration parts and service

Clerestory
restoration

Parts or SERVICE

Experienced restoration of historic clerestory & skylights by Virginia Carpenters.  Gepetto has the experience and shop tooling to solve anything from water leaks to full rebuild and fabrication in our shop.

agsdi-bitbucket

Build

agsdi-aspengrovestudios

Restore

agsdi-hand-leaf

Repair

7

As an experienced carpenter specializing in the restoration of 18th-century clerestory buildings in Virginia, I’ve encountered numerous challenges that arise from a general misunderstanding of these historical structures by untrained builders. Clerestory buildings, characterized by their high windows above eye level, were designed to provide natural light and ventilation, a concept often overlooked in modern architecture. This fundamental aspect of their design is frequently misunderstood, leading to improper renovations that compromise both the aesthetic and functional integrity of these historic buildings.

Clerestory windows illuminate many of Frank Lloyd Wright-designed interior spaces, especially the Usonian home designs, including the Zimmerman House and the Toufic Kalil Home. In addition to adding clerestory windows to residential structures, Wright also used rows of glass in more traditional settings, such as his Unity Temple, Annunciation Greek Orthodox, and the original library, the Buckner Building, on the campus of Florida Southern College in Lakeland. For Wright, the clerestory window was a design choice that satisfied his aesthetic and philosophic ideals.

Clerestory windows have become a mainstay of modern residential architecture. From the 1922 Schindler Chace house designed by the Austrian-born R. M. Schindler to the student designs of the Solar Decathlon competition, this type of fenestration is a popular and practical choice.

Remember that this “new” way of design is centuries old. Look up at the great sacred places across the world. Heavenly light becomes part of the prayerful experience in synagogues, cathedrals, and mosques throughout the ages, from Byzantine to Gothic to Modern structures like architect Alvar Alto‘s 1978 Church of the Assumption of Mary in Riola di Vergato, Italy.

Clerestory Restoration

Another common issue is the mismanagement of the clerestory windows themselves. These windows are crucial for light and air circulation, yet I’ve seen many cases where they have been inappropriately sealed or replaced with glass that doesn’t match the period. Such alterations not only disrupt the building’s historical character but also its internal climate control, which was originally designed to rely on natural ventilation. It’s essential to use restoration techniques that maintain the original functionality of these windows while preserving their historical appearance.

clerestory restoration virginia

In my work, I’ve seen many instances where untrained builders have attempted to “modernize” these structures without respecting their original design. For example, replacing original woodwork with modern materials not only detracts from the building’s historical authenticity but also affects its durability. The wood used in the 18th century was often old-growth timber, which is denser and more resistant to decay than most wood available today. Ignoring this, untrained builders often use less suitable materials, leading to a faster degradation of the structure.

Educating untrained builders about the historical and architectural significance of these structures is vital. Workshops and training programs on traditional carpentry methods and materials can bridge this knowledge gap. As someone deeply passionate about preserving our architectural heritage, I advocate for a collaborative approach where experienced craftsmen like myself work alongside newer builders. This not only ensures the structural and historical integrity of these clerestory buildings but also passes down valuable skills and knowledge to future generations of carpenters.

clerestory restoration virginia
clerestory restoration virginia

USING CLERESTORY in HOME OR OFFICE DESIGNS FOR ENERGY EFFICIENCY

USING CLERESTORY IN HOME OR OFFICE DESIGNS FOR ENERGY EFFICIENCY

Daylighting and Sunshading

Natural daylight from the northern window wall illuminates the entire building without glare, substantially reducing what is usually an room’s most significant energy cost, electric lighting. Ideally, overhead overhead lights won’t be needed during the day. Also, an open office layout allows daylight to be distributed throughout the building, providing more efficient heating and cooling. Eaves are designed to provide shade of interior walls in the summer reducing cooling costs dramatically.

Using Natural Ventilation

To reduce the need for electricity, a building is situated to receive maximum southern exposure for warmth and to take advantage of prevailing winds for natural ventilation. Using the sun’s heat in the winter and natural ventilation during warm months, the heating and cooling systems are not needed approximately 15 percent of the year if the natural design principles can be followed.  Extreme examples of this design principle are found in the Earthship designs of Michael Reynolds in New Mexico successfully colling a building in the desert sun.

natural ventilation using clerestories and prevailing winds
pool house clerestory restoration Homestead VA

Homestead Resort Pool Clerestory

The Homestead Resort and Hot Springs were purchased by the Omni hotel group in 2013 and from October 2021 to October 2023, the entire resort underwent a complete renovation, costing over $150 million.  Gepetto supplied many of the historically accurate elements to the renovation contractors.  

Mount Vernon Fences

Mount Vernon Fences

mount vernon historic restoration preservation millwork supplier
mount vernon historic restoration preservation millwork supplier
mount vernon historic restoration preservation millwork supplier
mount vernon historic restoration preservation millwork supplier
mount vernon historic restoration preservation millwork supplier
mount vernon historic restoration preservation millwork supplier
handmade smithed historic gate hinges

Full passthrough mortise joints.

hand smithed historic gate hinges

Hand smithed historically accurate gate hinges.

hand turned post architectural decorative elements
hand smithed gate latch hardware
hand smithed gate hinge hardware
hand smithed gate hinge hardware
handmade historic fencing with decorative flourish made to match historic records
hand smithed gate hinge hardware
historic mount vernon home under construction
Mount Vernon Historic Restoration Materials Supplier
Mount Vernon Historic Restoration Materials Supplier
Mount Vernon Historic Restoration Materials Supplier
Mount Vernon Historic Restoration Materials Supplier
Mount Vernon Historic Restoration Materials Supplier
Mount Vernon Historic Restoration Materials Supplier
Mount Vernon Historic Restoration Materials Supplier
Mount Vernon Historic Restoration Materials Supplier

Virginia, often referred to as the “Mother of Presidents,” boasts a rich historical heritage that includes the homes and estates of some of America’s most iconic figures. One such historic gem is the Mount Vernon Estate, the former home of George Washington, the first President of the United States. Over the years, this treasured piece of American history has faced numerous challenges in its restoration efforts. Similarly, Gepetto Millworks, a renowned supplier of historic architectural millwork, has played a pivotal role in preserving Virginia’s historic architecture through their museum-quality restoration projects. The struggles faced in restoring the Mount Vernon Estate and the valuable contributions of Gepetto Millworks has made to historic preservation projects throughout Virginia are featured in these pictures.

The Mount Vernon Estate: A National Treasure

Mount Vernon, located on the banks of the Potomac River in Fairfax County, Virginia, is a place of immense historical significance. George Washington’s Mount Vernon Estate and Gardens is not only a symbol of the Founding Father’s legacy but also a testament to the architectural splendor of its time. The estate comprises the iconic mansion, outbuildings, lush gardens, and scenic landscapes. However, the preservation of Mount Vernon has been an ongoing struggle marked by various challenges.

Restoration Challenges at Mount Vernon

a. Weathering and Aging: Mount Vernon, like many historical sites, has faced the relentless effects of time and weather. Harsh winters, humid summers, and unpredictable weather patterns have taken a toll on the estate’s structures and architectural elements.

b. Preservation Costs: The financial burden of maintaining and restoring a site of Mount Vernon’s magnitude is substantial. Funding for restoration efforts often falls short, leading to the need for creative solutions and partnerships.

c. Historical Authenticity: Striking a balance between preserving the estate’s historical authenticity and accommodating modern visitor needs can be a delicate task. Restorations must respect the past while providing an educational and enjoyable experience for present-day tourists.

d. Skilled Labor Shortages: Finding craftsmen and artisans with the skills necessary for historical restoration can be a daunting challenge. The need for expertise in traditional techniques adds complexity to restoration projects.

e. Conservation Efforts: Environmental concerns and conservation efforts demand that restoration projects adhere to strict guidelines and sustainable practices. Balancing these requirements with historic preservation can be a struggle.

Gepetto Millworks: A Beacon of Expertise

Amid these restoration challenges, Gepetto Millworks has emerged as a beacon of expertise and quality in partnership with Museum Resources Kerry Shackleford. Founded with a commitment to producing museum-quality architectural millwork, our Virginia-based company has made substantial contributions to the restoration of historic buildings throughout the state.

  1. Museum-Quality Restoration

Gepetto Millworks specializes in crafting architectural millwork with an unparalleled commitment to historical accuracy. Their artisans use traditional techniques and materials, ensuring that each piece is a faithful reproduction of the original. This dedication to museum-quality restoration has made Gepetto Millworks a trusted partner in preserving Virginia’s historic architecture.

  1. Craftsmanship and Expertise

Restoration projects require a high level of skill and craftsmanship, often involving intricate details and historical accuracy. Gepetto Millworks employs master craftsmen who possess the knowledge and experience to recreate historical millwork with precision and authenticity. Their expertise is invaluable in maintaining the integrity of Virginia’s historic buildings.

  1. Collaborations with Historic Sites

Gepetto Millworks has actively collaborated with historic sites across Virginia, including Mount Vernon, to provide custom millwork solutions. Their work not only enhances the aesthetics of these buildings but also ensures their long-term structural integrity. Such collaborations exemplify the company’s commitment to preserving Virginia’s rich history.

  1. Sustainability and Conservation

In an era of increased environmental awareness, Gepetto Millworks incorporates sustainable practices into their restoration projects. Their use of locally sourced materials, eco-friendly finishes, and adherence to conservation guidelines aligns with the broader goals of preserving historic sites while minimizing environmental impact.

The Symbiotic Relationship between Mill & Installation

The relationship between the restoration of Mount Vernon and the contributions of Gepetto Millworks exemplifies a symbiotic partnership rooted in shared values.  In historic time periods labor was more affordable, and hand tools were used for shaping – so the fence profiles where not machine or template consistent.  You’ll see that small nuance if you look at the pictures closely now.

  1. Historical Authenticity: Gepetto Millworks’ dedication to historical accuracy ensures that every piece of millwork they create for Mount Vernon aligns with the estate’s architectural heritage. Their work is a vital component in preserving the authenticity of this iconic historical site.
  2. Addressing Restoration Challenges: The challenges faced in restoring Mount Vernon, such as the shortage of skilled artisans and preservation costs, are mitigated by Gepetto Millworks’ expertise and commitment. Their skilled craftsmen contribute to the restoration process while offering cost-effective solutions.
  3. Education and Tourism: Mount Vernon serves as an educational resource and tourist attraction, and Gepetto Millworks’ contributions enhance visitors’ experiences. The meticulous restoration work adds value to the estate’s appeal, promoting historical education and tourism in Virginia.
  4. Sustainability and Conservation: Both Mount Vernon and Gepetto Millworks recognize the importance of sustainable practices in historic preservation. By aligning their efforts with conservation principles, they ensure that the estate’s restoration is not only historically accurate but also environmentally responsible.

The struggle to restore the Mount Vernon Estate and the dedication of Gepetto Millworks to preserving Virginia’s historic architecture are intertwined stories of commitment, expertise, and shared values. Mount Vernon stands as a testament to America’s past, and its restoration challenges reflect the broader issues faced by historic sites across the nation. Gepetto Millworks’ role in providing museum-quality architectural millwork showcases the critical importance of skilled craftsmanship and historical accuracy in preserving our heritage.  In the face of weathering, financial constraints, and the need for historical authenticity, the collaboration between Mount Vernon and Gepetto Millworks serves as a model for successful historic restoration projects. Together, they ensure that the legacy of George Washington and Virginia’s rich historical heritage will endure for generations to come, offering a glimpse into the past for visitors and an opportunity to learn from it.

custom arc and round Top doors,  gates & Windows

custom arc and round Top doors, gates & Windows

In the world of construction and preservation, few elements evoke the same sense of wonder and complexity as round windows in historic buildings. These architectural marvels have graced our cities for centuries, captivating the imagination with their intricate designs and timeless beauty. As a construction manager deeply involved in the restoration of historic structures, I have come to appreciate the unique challenges and rewards that come with the territory. In this narrative, I will explore the intricate world of round windows in historic buildings, shedding light on their complexity and the indispensable need for experienced millwork craftsmen, such as Gepetto Millwork, to handcraft these exquisite features rather than opting for on-site construction or less experienced manufacturers.

The Fascination with Historic Round Windows

Before diving into the specifics of round windows, it is essential to understand why these architectural elements hold such a special place in the hearts of preservationists, architects, and construction managers alike. Round windows, often referred to as oculi or rose windows, are not just functional openings to let light into a building; they are intricate works of art, often featuring intricate tracery, stained glass, and decorative detailing. They serve as both practical and aesthetic elements, offering glimpses of the world outside while simultaneously enhancing the building’s visual appeal.

The Complexity of Round Windows

a. Architectural Challenges

Historic round windows, unlike their rectangular counterparts, present a myriad of architectural challenges. Their curved shape defies the straightforward geometry that most modern construction methods are built upon. This complexity necessitates precise calculations, measurements, and a deep understanding of materials so as not to create weakness and structural failure.

b. Structural Integrity

One of the foremost concerns when dealing with round windows is ensuring structural integrity. These windows often occupy large portions of the building’s façade, which means they must withstand considerable loads and environmental stressors. Failing to address structural concerns could lead to costly and dangerous consequences, compromising the safety of the building and its occupants.

c. Historical Authenticity

Preserving the historical authenticity of a building is paramount in restoration projects. Round windows are often integral to a building’s historical identity, and any attempt to replace or modify them must be done with the utmost care and attention to detail. Using the wrong materials or techniques can irreparably damage the building’s historical integrity.

The Artistry of Round Window Design

a. Intricate Tracery

One of the most captivating aspects of round windows is their intricate tracery, which refers to the ornamental stonework or woodwork that forms the window’s framework. The design of tracery can range from simple geometric patterns to elaborate, flowing motifs that tell a story or convey religious symbolism. Crafting tracery requires not only technical skill but also a deep appreciation for the artistic and historical context in which the window exists.

b. Stained Glass

Stained glass is a hallmark of many historic round windows, adding a mesmerizing play of colors and light to the interior of the building. The creation of stained glass windows is a highly specialized craft that demands a deep understanding of glasswork and painting techniques. Each piece of glass must be meticulously chosen for its color and translucency, and the final composition must be both beautiful and structurally sound. The Role of Experienced Millwork Craftsmen

a. Artful Construction

Millwork refers to the crafting of wood elements for architectural purposes, and it is a crucial aspect of round window construction. The skills required for millwork are highly specialized, involving precision cutting, carving, and shaping of wood to create intricate designs. Experienced millwork craftsmen possess the knowledge and expertise necessary to execute the most intricate and historically accurate round window designs.

b. Gepetto Millwork: A Trusted Name

When it comes to entrusting the creation of round windows in historic buildings, Gepetto Millwork is a name that resonates throughout the industry. With a 20 year legacy of craftsmanship Matthew Wiley has earned a reputation for excellence and delivered on big projects. His dedication to preserving historical accuracy and attention to detail make them a preferred choice for construction managers and preservationists alike.

The Perils of On-Site Construction

a. Compromised Quality

Attempting to construct round windows on-site presents a host of challenges that can compromise the quality and authenticity of the final product. On-site construction lacks the controlled environment and specialized equipment necessary for crafting intricate designs and achieving precise measurements.

b. Delays and Cost Overruns

On-site construction of round windows often leads to delays and cost overruns. Any miscalculations or mistakes can result in significant setbacks, including the need for costly revisions and repairs. These delays can be especially problematic when working on historic restoration projects with tight timelines and budgets.

The Pitfalls of Less Experienced Manufacturers

a. Cookie-Cutter Approaches

Less experienced manufacturers may take a one-size-fits-all approach to round window production, neglecting the unique historical and architectural context of each project. This can result in generic, uninspired designs that fail to capture the essence of the building or the period in which it was constructed.

b. Lack of Expertise

Experienced millwork craftsmen, like those at Gepetto Millwork, possess a level of expertise that is simply unmatched by less experienced manufacturers. The intricate detailing, historical accuracy, and structural integrity of round windows require a depth of knowledge and skill that cannot be easily replicated. In the world of historic preservation and construction, round windows stand as testaments to the intersection of art and architecture. Their complexity and beauty captivate the imagination and inspire awe. Yet, these architectural marvels are not easily replicated or replaced, and their preservation demands the utmost care and expertise. As a frustrated construction manager, I have witnessed firsthand the challenges that come with attempting to construct or restore round windows without the involvement of experienced millwork craftsmen like Gepetto Millwork. The complexities of structural integrity, historical authenticity, and artistic design cannot be taken lightly. To do justice to these remarkable features of historic buildings, we must recognize the indispensable role of craftsmanship in their creation and restoration. The next time you gaze upon a historic round window, take a moment to appreciate the intricate tracery, the stained glass, and the centuries of artistry and craftsmanship that have gone into its creation. These windows are not just openings to the past; they are portals to a world where beauty and complexity converge, reminding us of the timeless allure of historic architecture.
Unique Restaurant Millwork

Unique Restaurant Millwork

Completely Unique

Collaborate with a master woodworker on your first or next restaurant design.

20 years of experience bringing wood to life in restaurants for unique experiences.

Feature Natural Beauty

Start your creative plan with a master woodworker and feature the natural beauty of wood.

With two decades of crafting vibrant and unique dining experiences
through expert woodworking in restaurants,
we breathe life into wood, making each piece tell a story of its own.

Unique Restaurant Millwork

Si restaurant was a creative project in 2007 where wood brought to life in a very small space. Fitting the tiny space with off the shelf tables and chairs would have severely limited the function, and profitability of the restaurant. The owner approached us for assistance, seeking architectural help to build a space with a warm and comfortable atmosphere and a fluid layout to allow servers and waitresses to work smoothly. At it’s center, in the horizontal layout the architect designed a kidney-shaped table as a high-top that could seat any larger parties or family dining but needed confidence that we could make a structure strong enough while saving space. Massive large turnings became the legs. Standard height tables line the back wall and we increased seating capacity by forming a bench the complete length. Hard to notice in these photos but the bench seat turns the edge with a solid bent plywood showcasing the grain.

Wood Grain Theme

The natural wood grain brought a unified theme and saved on cost. The central visual flourish at the center incorporates the wine rack. Adding large circles to contrast all the straight lines, as well as confound the eye as to the method of construction, gave the space a bold and memorable arc. Two dark grain grain relics are held up creating a tension and mystery while delighting the eye as it travels up. The community table stands on hand turned solid legs, showcasing a rare grain profile but pragmatically saving floor space to make the small space appear larger. All the millwork showcased an end grain texture, lending the tabletop a distinct appearance divergent from traditional restaurant tables that was unheard of in 2007, and all the rage now.

Design Collaboration

Other practical pieces aren’t seen in the pictures. For example to ensure customer turnover, crucial for the restaurant’s survival in such a confined space, we opted not to include cushions on the seats; excessively comfortable seating might encourage patrons to linger for extended periods. In choosing Gepetto as your supplier, you get to work directly with me and can rely on me to collaborate with you for uninque presentation, as well as cost saving ideas that come directly from 20+ years of shop management experience. Just phone me up to talk through your creative interior that needs custom wood fabrication: ‪804-938-2094‬

virginia creative restaurant builder
completely unique restaurant millwork
virginia custom restaurant builder
virginia custom restaurant builder
virginia custom restaurant builder
virginia custom restaurant builder
virginia custom restaurant builder
https://gepettomillworks.com/commercial-millwork/restaurant-fittings/

Delivery & Install

Custom Fit

Handmade

Made IN VA

Unique Restaurant Millwork

Collaborate with a master woodworker on your first or next restaurant design. 20 years of experience bringing wood to life in restaurants for unique experiences.Start your creative plan with a master woodworker and feature the natural beauty of wood. With two decades...

Farmhouse Chic Rustic REstaurant Furnishing

Contact Matthew Wiley at Gepetto Millworks 804-938-2094 for custom restaurant pieces that ensure your space and presentation are unique!  Gepetto builds the made to order millwork from their shop in the hills outside of Charlottesville so you are supporting the local...

Restaurant Builder – Complex Artistic Fittings and Furnishings for Restaurants

COMPLEX ARTISTIC FITTINGS AND FURNISHINGS FOR RESTAURANTSWe're here in Washington DC finishing up install cleanup at M street and 11 th for Supra Restaurant.  The restaurant's beginning is an interesting story in innovation starting on Kickstarter and finished with...

Built to suit in-home bar : custom wood bar order

You want an empressive entertainment space. We can build anything you'd like!If you'd like your mancave to have that rustic feel. A hunting lodge meets olde english pub?Built to suit in-home bar Are you designing your dream home? We will design and build the ultimate...

Gepetto Millworks has carved a niche for itself in addressing spatial challenges while delivering sophisticated and stylish woodworking solutions for restaurants in Virginia, Maryland, and Washington DC. With a thorough understanding of the unique spatial problems encountered by restaurants in these regions, our craftsmen expertly create pieces that not only maximize the utility of space but also significantly elevate the aesthetic appeal of the establishments bringing in those social media mentions!

Understanding Spatial Challenges

Restaurants in bustling urban areas of Virginia, Maryland, and Washington DC often operate within confined spaces. Gepetto Millworks meticulously analyzes the dimensions and layout of each space to craft furniture and wooden installations that align seamlessly with the available area. They utilize innovative design techniques to ensure that each piece of furniture is both functional and compact, facilitating smooth movement within the restaurant while accommodating the maximum number of patrons.

Bespoke Design Solutions

The Gepetto Millworks team engages closely with restaurant owners and architects to comprehend their vision and requirements. With a keen eye for detail, they develop custom designs that reflect the brand’s identity while tackling spatial constraints. Whether the client desires a classic or contemporary ambiance, Gepetto Millworks delivers woodworking solutions that encapsulate the desired theme while optimizing space utility.

Material Selection and Craftsmanship

Selecting the finest materials is at the core of Gepetto Millworks’ operation. The company sources high-quality wood known for its durability and aesthetic versatility. Each piece undergoes a meticulous crafting process, where artisans with years of experience shape and assemble the wood with precision and care. The result is a collection of robust and beautiful furniture and installations that stand the test of time while enhancing the allure of the restaurant.

Innovative Features

Spatial problems often require inventive solutions. Gepetto Millworks introduces clever features into their designs to further assist with space management. For example, adjustable and foldable tables allow restaurants to easily modify the layout to suit different events or peak hours. Integrated storage solutions help in organizing and decluttering the space, making it appear larger and more inviting.

Aesthetic Cohesiveness

Maintaining a harmonious visual flow within a restaurant is crucial for creating a pleasant dining environment. Gepetto Millworks pays careful attention to ensuring that all wooden elements within the space complement each other and contribute to a cohesive aesthetic narrative. The wood’s color, grain, and finish are thoughtfully selected to align with the restaurant’s overall design scheme, creating an environment that is visually pleasing and welcoming.

Customer-Collaboration with Master Woodworker

Understanding the client’s needs and expectations is paramount for Gepetto Millworks. The company maintains open communication with restaurant owners throughout the design and manufacturing process, welcoming feedback and making necessary adjustments to achieve a product that meets, and often exceeds, the client’s expectations. This collaborative approach allows for the creation of spaces that are not only beautiful and functional but also uniquely tailored to each restaurant’s character and brand.

Case Studies of Success

Gepetto Millworks has a portfolio rich with success stories from restaurants spread across Virginia, Maryland, and Washington DC. Each case study is a testament to the company’s ability to transform spaces through expert woodworking and innovative design solutions. Whether it’s a quaint café looking to maximize seating capacity without compromising comfort or a high-end restaurant aiming to offer an unparalleled aesthetic experience, Gepetto Millworks has consistently delivered results that have left clients immensely satisfied.

With a commitment to excellence in design, craftsmanship, and customer service, Matthew Wiley @ Gepetto Millworks has established itself as a leader in providing woodworking solutions that address spatial challenges faced by restaurants in Virginia, Maryland, and Washington DC. The company’s dedicated team, innovative approach, and attention to detail ensure that each project is executed with precision and flair, resulting in restaurant spaces that are not only functional but also enchantingly beautiful. Through their expertise, Gepetto Millworks continues to contribute to creating dining spaces that are memorable, comfortable, and reflective of the unique brands they represent.

Custom Wood Turning for Historic Restoration

Custom Wood Turning for Historic Restoration

Handmade Turned wood rounds

We hand turn solid wood round pieces for historic restoration projects.  That means that we pickup the damaged or worn parts to recreate them in our Charlottesville VA shop.

k

CUSTOM

REPAIR

HAND
MADE

CALL MATT

If you are searching for unique pieces for historic restoration building – call Matthew to discuss your needs!  We can build whatever you need, from whatever time period you are restoring.  These hand carved or turned pieces are being delivered to New Kent Virginia 

 

804.938.2094

solid wood round historic hand turning services

Handmade wood turnings made to order by Virginia craftsmen.  Whatever your project calls for we will make it to your specifications.  First step will be getting ‘shop drawings’ done, completely accurate architectural drawings.  From there we just need time!

Watch Them Turn Solid Wood

@gepetto.millworks Matt is making #handturned column bases from solid mahogany today in the shop - if you don’t think that you can find the parts and pieces for your #historicrenovation ♬ original sound - Gepettomillworks

GEPETTO CRAFTSMEN MAKE

Shop Magic

Hand Turned Solid Wood Column Base for Historic Restoration
Hand Turned Solid Wood Column Base for Historic Restoration

A Legacy in Woodworking

At the heart of the historic restoration narrative lies Gepetto Millworks, a revered name in the woodworking realm, known for its unrivaled dedication to traditional craftsmanship. Situated in the woodlands of Virginia, Gepetto Millworks boasts a legacy spanning three generations, breathing life into the art of woodturning and historic restoration. Starting with Robert Wiley, now retired, Matt Wiley was trained by the demands of rural western Virginia farm life. Pragmatic attention to planning and time management crucial for farm life made Matt ready to manage a Millwork Shop. Robert’s 40 years of carpentry experience passed on to Matt a wide understanding of the building trades, common problems and historic solutions not readily available on Google or Youtube. Starting in 2022 now the 3rd generation began their apprenticeship under Matt with the understanding that fine wine takes time to mature! Gepetto now operates the shop facility from a nearly hidden hollow of 100 acres of farmland in the historic hills around Charlottesville VA.

The Art of Turning Solid Wood Pieces

The process of turning solid wood pieces is a harmonious blend of skill, precision, and patience. This age-old technique involves placing a wood blank on a lathe and shaping it using various cutting tools while it spins. For historic restoration, this technique offers the ability to recreate ornate profiles and subtle curves that were the hallmarks of architectural decoration in a bygone era where time & labor were less costly. Gepetto runs a very small staff of highly experienced craftsmen, so that projects are completed in a timely manner – and the trade skills and secrets are maintained. If you are seeking a unique piece – don’t worry, we’ve heard of it – and can recreate it accurately!

Column Bases: Echoes of Elegance

Column bases are architectural features that have graced structures for centuries, each reflecting the design trends of their time. In historic restoration, crafting column bases involves not just replicating their appearance but also understanding the construction techniques and materials that were prevalent during the structure’s era. Gepetto Millworks’ mastery shines in meticulously recreating column bases, capturing the very essence of the original design while ensuring structural integrity. We can craft a base from a single piece of solid mahogany so that environmental stressors are less likely to damage the piece. Historic building methods often have pragmatic reasons for their implementation. While we are capable of making a plywood style layered composite, the effective durability of a solid slab of weather durable mahogany is higher than a manufactured material. Architectural millwork encompasses a vast array of components, from intricate cornices to elaborate friezes. In historic restoration, these elements are the pièce de résistance, embodying the grandeur and attention to detail that defined the architecture of yesteryears. The artisans at Gepetto Millworks approach architectural millwork with a profound respect for tradition, using age-old techniques to replicate every fine detail, ensuring an authentic restoration that stands the test of time.
Hand Turned Solid Wood Column Base for Historic Restoration
Hand Turned Solid Wood Column Base for Historic Restoration

Turned Solid Wood Pieces

Historic restoration is a noble endeavor that bridges the gap between the past and the present, preserving the essence of bygone eras for generations to come. One of the essential elements in such restoration projects is the art of turning solid wood pieces. Gepetto craftsmen are some of the only professional supply options for general contractors, architects and restoration specialists looking to recreate solid wood pieces. Delve into the intricate world of historic restoration construction with us! That world where turned wood components like column bases, balustrades, and newels, meticulously handcrafted on the wood lathes of Gepetto Millworks in Virginia continue to be exemplary producers of timeless craftsmanship that lasts centuries.

The Essence of Historic Restoration

Historic restoration construction involves a delicate balance between honoring the architectural legacy of a structure and ensuring its continued viability for modern use. In this context, turned solid wood pieces play a pivotal role because so many general contractors are not aware of services like Gepetto provides. The general contractor of today does not have an army of skilled woodworkers supplying their job sites any longer as in the historic time periods we are task to restore. You can return to the essence of an era, preserving the stylistic intricacies that defined the architectural preferences of that past time period. These pieces when installed properly continue the irreplaceable charm of the historic building.

Column Bases: Echoes of Elegance

Column bases are architectural features that have graced structures for centuries, each reflecting the design trends of their time. In historic restoration, crafting column bases involves not just replicating their appearance but also understanding the construction techniques and materials that were prevalent during the structure’s era. Gepetto Millworks’ mastery shines in meticulously recreating column bases, capturing the very essence of the original design while ensuring structural integrity. We can craft a base from a single piece of solid mahogany so that environmental stressors are less likely to damage the piece. Historic building methods often have pragmatic reasons for their implementation. While we are capable of making a plywood style layered composite, the effective durability of a solid slab of weather durable mahogany is higher than a manufactured material. Architectural millwork encompasses a vast array of components, from intricate cornices to elaborate friezes. In historic restoration, these elements are the pièce de résistance, embodying the grandeur and attention to detail that defined the architecture of yesteryears. The artisans at Gepetto Millworks approach architectural millwork with a profound respect for tradition, using age-old techniques to replicate every fine detail, ensuring an authentic restoration that stands the test of time.

Balustrades and Newels: Stairways to History

Balustrades and newels are often the visual centerpiece of historic buildings centered around the staircase. Adorning staircases with intricate designs that were once the high style elegance in that era. In the meticulous restoration of these components, Gepetto Millworks’ woodturning expertise comes to the fore. Every spindle, rail, and newel is handcrafted with the utmost care, ensuring that the soul of the original design is captured and the handmade nuances remain. What sets Gepetto Millworks apart is not just its remarkable craftsmanship, but its commitment to historical accuracy. The artisans delve deep into architectural records, scrutinizing historical documents and photographs to unravel the design elements of anything lost to the past. This dedication extends to sourcing the right wood species, using traditional joinery methods, and applying authentic finishes, ensuring that each turned wood piece is a faithful representation of its era.

Preservation Through Education

The legacy of historic restoration lives on through education. Gepetto Millworks recognizes the importance of passing on the torch of craftsmanship to the next generation. The woodworking workshops and apprenticeships offered by the millworks provide budding artisans with the opportunity to learn the nuances of turning solid wood pieces, perpetuating a tradition that might otherwise fade away. In the realm of historic restoration construction, turned solid wood pieces embody the essence of eras long past. Gepetto Millworks, nestled in the heart of Virginia, breathes life into this legacy, crafting column bases, architectural millwork, balustrades, and newels that stand as testaments to the artistry of yore. As we gaze upon these masterpieces, we are reminded that the past is not merely history; it is a living, breathing entity that continues to enrich our present and inspire our future.

Timeline

Historic Building Tax Credits

Maximizing Historic Building Tax Credits with Gepetto Millworks’ Authentic Wood Architectural Elements Restoring historic buildings is both a labor of love and a commitment to preserving cultural heritage. While the process is rewarding, it can also be financially...

VCU SCOTT HOUSE Window Restoration

                  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...

Accoya Approved Manufacturer VA

We have been using Accoya Acetylated wood for exterior applications since it's introduction into the United States market in 2012. Acetylated wood stands truer and weather's better - read the acdemic articles below to start your education for specifiying the...

Accoya Wood Window Builder VA

Windows made of Accoya Acetylated Wood In the heart of the Blue Ridge Mountains craftsmanship meets innovation in the form of Solid Wood windows made at Gepetto of Accoya Acetylated Wood.  Your new windows will stand as a testament to old world historic quality and...

Clerestory Restoration Virginia

Airflow and Comfort in Pre-Air-Conditioning Time Periods

A Focus on Virginia

Clerestory windows have played a significant role in architectural design throughout history. These windows are characterized by their placement high on the walls of a structure, allowing natural light to flood the interior while facilitating airflow and ventilation. In pre-air-conditioning eras, such as in the state of Virginia, clerestory windows were particularly valued for their ability to improve indoor comfort. This article explores the restoration of clerestory windows for airflow and comfort in pre-air-conditioning time periods, with a specific focus on the work conducted by Gepetto Millworks. 

Historical Significance of Clerestory Windows

Clerestory windows have a rich history dating back to ancient times. The concept of the clerestory developed as a solution to challenges faced by architects and builders in creating well-lit and ventilated spaces. The utilization of vertical slabs of stone and narrow windows allowed for the admission of light and air, while maintaining the structural integrity of the building. This architectural innovation eventually found its way into churches, cathedrals, and other religious structures, where it became an essential element in creating awe-inspiring spaces.

The Role of Clerestory Windows in Pre-Air-Conditioning Times

Prior to the advent of air conditioning, buildings in Virginia and across the United States relied on passive cooling techniques to maintain comfortable indoor temperatures. Clerestory windows played a crucial role in this regard. By strategically placing these windows high on the walls, architects capitalized on the stack effect, a natural ventilation phenomenon that occurs when hot air rises and escapes through upper-level openings, drawing in cooler air from lower levels. The clerestory windows acted as exhaust vents, expelling warm air while simultaneously allowing fresh, cool air to enter the space. This process facilitated airflow, reducing stuffiness and improving overall comfort.

Preservation and Restoration of Clerestory Windows

With the passage of time and changing architectural trends, many historic buildings with clerestory windows fell into disrepair. However, there has been a recent resurgence of interest in restoring these windows to their former glory. Gepetto Millworks, a prominent restoration company, has been at the forefront of this movement in Virginia.

The restoration process begins with a thorough examination of the existing clerestory windows. Gepetto Millworks’ team of experts carefully assesses the condition of the windows, including the frames, glass panes, and any decorative elements. Preservation and restoration efforts aim to retain as much of the original material as possible, ensuring historical accuracy.

Gepetto Millworks utilizes traditional craftsmanship techniques to repair and replace damaged components. For instance, if the wooden frames show signs of decay, they are meticulously restored using age-appropriate joinery methods and durable wood species, such as mahogany or oak. Similarly, damaged glass panes are replaced with historically accurate replicas, matching the original design and ensuring optimal transparency.

Maximizing Airflow and Comfort

In the restoration process, Gepetto Millworks pays particular attention to optimizing the airflow and comfort provided by clerestory windows. Historical accuracy is maintained while integrating modern advancements in energy efficiency and comfort.

To ensure effective ventilation, Gepetto Millworks carefully adjusts the size and positioning of the windows, considering factors such as prevailing wind directions, sun exposure, and the building’s orientation. By tailoring these aspects to specific locations in Virginia, the company optimizes natural airflow patterns, promoting a comfortable and healthy indoor environment.

Gepetto Millworks also employs advanced weather sealing techniques to reduce air leakage. This not only enhances the energy efficiency of the restored windows but also prevents unwanted drafts and moisture infiltration, preserving the building’s structural integrity.

Benefits of Clerestory Window Restoration

The restoration of clerestory windows brings numerous benefits to both historic buildings and their occupants.

Preservation of Cultural Heritage: By restoring clerestory windows, Gepetto Millworks helps preserve the architectural heritage of Virginia. These windows are significant cultural artifacts that contribute to the historical fabric of the state and reflect the craftsmanship of a bygone era.

Improved Natural Lighting: Clerestory windows allow abundant natural light to enter the interior, reducing the need for artificial lighting during daylight hours. This enhances visual comfort, minimizes energy consumption, and creates a more aesthetically pleasing environment.

Enhanced Ventilation: Restored clerestory windows facilitate efficient airflow, promoting natural ventilation and reducing the reliance on mechanical cooling systems. This not only improves indoor air quality but also decreases energy consumption and the associated carbon footprint.

Increased Comfort: Properly restored clerestory windows contribute to a more comfortable indoor environment by reducing humidity, balancing temperatures, and minimizing the occurrence of stagnant air. Occupants can enjoy a fresh and pleasant atmosphere, reminiscent of the pre-air-conditioning era.

The restoration of clerestory windows in Virginia is a testament to the dedication and expertise of companies like Gepetto Millworks. By breathing new life into these architectural elements, they revive the timeless benefits of natural lighting and ventilation. As buildings adapt to modern energy-efficiency standards, the restoration of clerestory windows becomes an invaluable endeavor to bridge the gap between historical preservation and contemporary comfort.

@gepetto.millworks

One of the interesting #architectural elements Gepetto Millworks often receives calls to replace, or rebuild are #skylight and #Clerestory from the era where light was just as precious as space. The light bulb was only invented in 1879, and the grid to support it would be years to follow! Today we are one of the few shops producing #handjoinery and we have replaced and repaired rooftop light systems from South Carolina to Maryland. Give me a call at 804-938-2094 to discuss replacing or restoring one in your project.

♬ original sound - Gepettomillworks
@gepetto.millworks

Custom made #historic #replica #historicrestoration serving general contractors and builders across #virginia #northcarolina #southcarolina #maryland

♬ original sound - Gepettomillworks
virginia clerestory service and restoration
virginia clerestory builder restoration
virginia clerestory restoration supplier

In architecture, a clerestory (/ˈklɪərstɔːri/ KLEER-stor-ee; lit. ’clear storey’, also clearstory, clearstorey, or overstorey) is a high section of wall that contains windows above eye level. Its purpose is to admit light, fresh air, or both.

Historically, clerestory denoted an upper level of a Roman basilica or of the nave of a Romanesque or Gothic church, the walls of which rise above the rooflines of the lower aisles and are pierced with windows.

Daylighting is the practice of placing windows, skylights, other openings, and reflective surfaces so that sunlight (direct or indirect) can provide effective internal lighting. Particular attention is given to daylighting while designing a building when the aim is to maximize visual comfort or to reduce energy use. Energy savings can be achieved from the reduced use of artificial (electric) lighting or from passive solar heating. Artificial lighting energy use can be reduced by simply installing fewer electric lights where daylight is present or by automatically dimming/switching off electric lights in response to the presence of daylight – a process known as daylight harvesting.

The amount of daylight received in an internal space can be analyzed by measuring illuminance on a grid or undertaking a daylight factor calculation. Computer programs such as Radiance allow an architect or engineer to quickly calculate benefits of a particular design. The human eye’s response to light is non-linear, so a more even distribution of the same amount of light makes a room appear brighter.

Unique wooden and Historic Window Makers in the South East US

Unique wooden and Historic Window Makers in the South East US

Windows are not only functional elements in a building but also serve as aesthetic highlights, especially in historic structures. The South East United States boasts a rich architectural heritage, and preserving the authenticity of historic buildings is of paramount importance. In this article, we will explore the world of unique wooden window makers in the South East US, with a special focus on Gepetto Millworks completed construction project portfolio. Our job history and qualifications highlight our unique and notable contributions to the restoration of the Montgomery Building in Spartanburg, SC and the Bull Street District Mental Hospital renovation in Columbia, SC.

Window Maker in the South East United States

Gepetto Millworks owned and operated by Matthew Wiley with his wife Pamela became a renowned window maker based in the South East US, by starting in one of the oldest standing neighborhoods on the continent : Church Hill Richmond. The word spread fast as Matthew built to order and matched historic trims, embellishments and other unique elements that make history come alive in historic homes, churches, theaters and restaruants. Specializing in crafting historically accurate unique wooden windows for historic structures soon caught the attention of restoration specialists from Williamsburg VA’s historic district. With decades of experience, Gepetto is now an approved vendor to the National Parks Services & Pentagon specialist provider for historic military buildings. Our unwavering commitment to quality, craftsmanship, and attention to hand built detail from the blue ridge near Charlottesville VA established us as a leader in the field.

The Montgomery Building, Spartanburg, SC brought the largest order for historic windows ever seen by the Gepetto shop. Renovating an iconic landmark with a rich history in the center of Spartansburg made for an order of 940 windows on this 24 story building. Built in 1924, it was the first high-rise building in Spartanburg and South Carolina. Gepetto Millworks was entrusted with the task of restoring and replicating the building’s historic windows, ensuring the preservation of its original character as it evolved into a mixed use modern development with shops, condos and a full set of amenities. Gepetto’s extensive knowledge of period-specific window design and construction techniques Matthew successfully recreated the historic windows but added energy efficient weather beating parts seamlessly blending old-world charm with modern functionality. The windows underwent full durability testing before being ordered, as due dilligence would suggest. This video shows the windows under hurricane strength wind forces to test their breaking point<<

South East Washington DC historic window maker
@gepetto.millworks

Our windows have withsstood tornadoes and pressure tests before installation - they passed, and they last!

♬ Pressure - EBEN & Trias
Southeast window maker for historic restorations

The Bull Street District renovation centers around the Historic Mental Hospital in downtownColumbia, SC. One of the first facilities to provide mental health services in the country it holds significant historical importance!  As part of a major renovation project aimed at transforming the hospital into a vibrant mixed-use development with baseball dimond, urban shopping like REI now anchors a full set of modern amenities to this historic campus where they raised their own food. Gepetto Millworks played a crucial role supplying the windows and millwork elements that qualify as Historic Tax Credit building materials. Our expertise in crafting windows that adhere to the strict guidelines of historical preservation helped breathe new life into the building while maintaining its architectural integrity.  Now residents walk their dogs under the beautiful living history of the mature trees on the campus.

Unique Qualifications – Customization and Replication

Gepetto Millworks specializes in the customization and replication of historic windows down to the panes of glass. Our skilled artisans meticulously note original window designs, materials, and construction techniques to ensure the accurate reproduction of frames, sashes and trims that add up to be indistinguishable from the originals when fully installed. Attention to detail while meeting all construction timelines is why large general contractors rely on Gepetto exclusively for projects at this scale.

Material Selection and Craftsmanship

The choice of materials is vital when recreating historic windows. Gepetto Millworks sources high-quality, sustainable wood that matches the original species used in the historic windows. Through their exceptional craftsmanship, they transform raw materials into intricate, durable, and beautiful window components that stand the test of time.

Preservation Expertise:

Preservation projects demand a deep understanding of how species of wood interact, how it will be machined into shape, and the order of installation to match historical preservation. Gepetto Millworks generously shares their expertise with contractors installing their products as woodworking is becoming a lost art with most commercial windows choosing aluminum for their material  Gepetto ensures adherance to the authentic style and proportions of the era in which the building was constructed even if example windows are destroyed beyond recovery.

Impact and Legacy:

The work of Gepetto Millworks restoring historic windows extends beyond the mere physical preservation of structures. By meticulously replicating windows, trim, glass panes and sashes, they contribute to the overall cultural and historical heritage of the South East United States. Dedication to craftsmanship and historical accuracy ensures that future generations can appreciate and understand the architectural achievements of the past.  If the windows in your home or building have lasted 200 years already, you do have a safe and reliable alternative to the plastics, vinyls, and metals that cloud the current marketplace.  Ask your accountant to amortize the cost of the windows over 200 years as you get a quote – it puts the whole process into perspective.

Preserving historic structures requires a delicate balance between maintaining authenticity and meeting modern functionality standards. Gepetto Millworks can apply UV Coatings, Weather Stripping and other small nuances that bring the historic window up to all energy efficiency expectations. Through exceptional skills and creative problem solvoing we have made significant contributions to the restoration and replication of historic windows across the eastern seaboard. With notable projects like the Montgomery Building in Spartanburg, SC, and the Bull Street District Mental Hospital in Columbia, SC, Gepetto Millworks continues to leave an indelible mark on the South East US’s regional architectural heritage.