(March 10, 2019: Conclusions in this post have since been corrected/updated, given new evidence.)
We were lucky to visit another American System Built Home (ASBH) last week. Linda’s loving care is evident in her model AA202. Her house is for sale and we hope it lands in the hands of an equally-compassionate steward.
During the tour, we confirmed that our home and the AA202 share many details, including common millwork, like the base-board shoe trim.
Base trim wood is among most abused in a home; kicked with feet, knocked with chairs and vacuums, and suffering sun, carpet abrasion and inattentive re-finishing. Linda was careful to match the trim in her renovations and maintained it to a very high standard. We have been gradually doing the same. First, we matched the design in rooms where it had been lost, like in the bathroom and under kitchen cabinets.
Now, we’re repairing damaged or marred sections of the original shoe trim. Where we can save the original wood, we do. Where we can’t, we have made exact reproductions using age-appropriate reclaimed birch and the amber shellac finish found throughout the home.
Studying the original milled woodwork reveals the functional brilliance of the design. Specifically, the only 90° angle is on the corner where the trim and wall meet. A 93° angle on the bottom back edge ensures a tight fit on both the wall and floor seams. Importantly, the more acute 87° angle on the top lip ensures a high contrast sun shadow to create a subtle horizontal line at the very base of a wall.
Subtleties like these come at a price. In order to recreate the geometries, a woodworker must fine-tune a table saw to run three precise subsequent passes in which the blade height, width and angle come together to create a seamless inset 30° angle. A gap or an overshoot can’t be repaired, so mistakes create expensive scrap of priceless wood.
While removing and repairing a section yesterday, we were reminded that we’re not the first to experience this cutting challenge. One hundred years ago, a millworker at the Arthur L Richards Co. (Frank Lloyd Wright’s marketing partner and supplier of pre-cut lumber for ASBHs) made sure to take credit for his/her work with an ink imprint – complete with typo – on the back of one board. It has been cleaned up and nailed back in place, securing the story for a future steward to rediscover.