Restoration Tip ~ Short lengths of replacement molding can be cast, saving the cost of having a custom knife profile cut at a millwork shop for reproduction wood molding.
Custom knives to reproduce a molding profile can cost $75 to $200—depending on the millwork shop and the size and complexity of the molding. When you only need a short piece, it may be cost-prohibitive to have a knife cut. As shown in the accompanying photo, I have had success casting short sections of molding to solve this dilemma.
In the example shown, I needed about 10 inches of a small Federal-style molding to replace short pieces thrown out when a door surround was fitted with a screen door in the mid-twentieth century. I made a casting mold using a surviving piece of the wood molding and cast several short pieces with epoxy wood filler. Once cured and cleaned up, they were cut with a miter saw and installed as shown.
The full process is illustrated with photos in Chapter 13 of “Restoring Your Historic House, The Comprehensive Guide for Homeowners.”
Signed and personalized copies of the award-winning and bestselling 720-page hardcover book are available from the author in our online shop at YourHistoricHouse.com/shop/.
Our shop also carries other select preservation and restoration titles, including the classic “A Field Guide to American Houses” by Virginia McAllester. Save with our multi-book combo packs!
© Scott T. Hanson 2024.
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