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Restoring historic houses with modern cabinetry

Full Circle Design Works, a St. Louis-based builder, specializes in the renovation and restoration of historic properties, focusing on integrating modern, frameless cabinetry into these century-old structures. The company operates its own modern shop, producing contemporary cabinets, man doors, trim, specialty mouldings, and custom furniture. While 75% of their work involves residential renovations and additions, the remaining 25% is new construction. A key differentiator for Full Circle is its in-house shop facility, allowing them to handle a wide range of custom millwork and cabinet needs, making them a preferred choice for architects seeking highly detailed work. The majority of Full Circle's projects involve extensive gut rehabs, where everything except some original walls is removed and then rebuilt. Some of these rehabs qualify for historic tax credits, necessitating the restoration of interiors to match original millwork details. The company frequently undertakes kitchen and bath renovations within these historic settings. Renovation work is particularly prevalent in various historic areas of St. Louis City, as well as wealthier suburban towns like Clayton and Ladue, where century-old homes are well-maintained. A notable project involved creating a 1¾-inch thick door with distinct designs on each side: a five-panel configuration for the dining room and five equal horizontal panels on the other side, showcasing the company's ability to tackle complex custom fabrication. Despite working with 100-year-old buildings, Full Circle's cabinetry aesthetic is distinctly contemporary and frameless. They construct cabinet boxes using melamine and maple on MDF or particleboard, with custom veneers for doors, drawer fronts, and finished ends. Maple veneer is treated with a post-catalyzed conversion varnish, consistent with the finish on doors and drawer fronts. This contemporary style is Full Circle's niche, standing apart from the traditional five-piece doors and crown mouldings common in St. Louis. The blend of contemporary cabinets with original running trim, base, casing, and doors creates a harmonious and visually appealing contrast. Matching the original look often requires creating new elements, as original casing and baseboards are rarely in good condition after a century. Full Circle specializes in fabricating new pieces that meticulously match original profiles and materials. Their commitment to precision is evident in their 2mm tolerance for cabinet reveals, a tighter standard than many other shops. As a general contractor, Full Circle also supplies its job sites with matching sills and plinths, ensuring consistency and helping to maintain project schedules. Collaborative work with architects allows them to contribute to initial project development, offer samples, and identify potential issues early on. Full Circle employs 10 people, with three dedicated to the shop, which moved to a larger 10,000-square-foot facility (a former dairy) two years prior. They utilize KCD software for design and EnRoute to feed work to their CNC router. The shop's workflow encompasses edgebanding, veneering, cutting, sanding, a spray booth, and assembly. A separate solid wood section handles jambs and other components. Equipment includes a Streibig Compact Plus vertical panel saw, a C.R. Onsrud 145M12 Mate series CNC router, Biesse Artech Levia 220 widebelt sander, and Biesse Polymac Akron 420ER edgebander. They also have two veneer presses, a Felder AD 41 planer-jointer, Felder KF7X combination machines, and a Casadei 24-inch surface planer. Finishing is done in-house using Chem-Craft post-catalyzed conversion varnish in a Col-Met spray booth. The company primarily uses Blum hardware, including the Legrabox metal drawer system, and some Grass hardware. The new facility is largely powered by solar panels, significantly reducing electricity costs. Future plans include acquiring an edgebander with premill capabilities and a widebelt sander with advanced technology to improve veneer sanding. Full Circle also aims to expand its specialty low-volume part production via CNC and custom cabinetwork for other general contractors, fostering collaborations with metal fabricators for wood components. #HistoricRenovation #ModernCabinetry #CustomMillwork #WoodworkingShop #HomeDesign #ArchitecturalDesign #CNCManufacturing #SustainablePractices #RenovationProjects #HistoricRenovation #ModernCabinetry #CustomMillwork #WoodworkingShop #HomeDesign #ArchitecturalDesign #CNCManufacturing #SustainablePractices #RenovationProjects
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