A couple of years ago, I was called by Dan Hellmuth of Hellmuth and Bicknesse Architects to work on a new green building that they were designing. I had worked with Dan previously on Washington University’s Living Learning Center and was glad to hear from him again. For me, the new job was similar to the Living Learning Center – trees from the property were going to be milled and the lumber was going to be used to make finished products throughout the house. The new building wasn’t trying to be the greenest building in the U.S., like the Living Learning Center, but it was designed to be very energy efficient with structural insulated panels (SIPS) and geothermal heating and cooling.

The property had about 80 acres of forest comprised of eastern red cedar, oak and hickory, along with a sprinkling of sugar maple and ash. The best trees were white oaks in the 24″ diameter range, some of which had veneer-grade butt logs (which means they were perfect, straight-grained and knot free). Most of the trees were slightly lower-grade and smaller, but still nice. The smallest were the cedars, which are considered invasive and were scheduled to be removed.

White oak logs on the landing waiting to be milled.

My choice of logs to harvest was limited by the terrain, which ranged from hilly to mountainous. Only one inclined ridge allowed reasonable access to the better logs. The rest of the forest housed bigger trees that will probably never be cut – it is just too difficult to get the logs out. Even spots that looked reasonably flat were only so in relation to the steep drop-offs. Often it was so steep that I had trouble getting the Bobcat back up to the landing, even if I wasn’t moving a log.

Once I got the logs out and back to my mill, I cut them and either air-dried or kiln-dried the lumber depending on their final use (kiln-dried goes inside, air-dried goes outside). The white oak was used for the deck, the boat dock and interior doors. The cedar was slated to be used as siding for the house, but that was changed to reclaimed barn siding and the cedar was moved indoors to be flooring in the loft areas. The smaller amount of ash, maple and hickory haven’t been used yet and are waiting their turn, most likely for future furniture.

Interestingly enough, two areas of woodwork in the house that I am most proud of, did not use wood from the property. We built the entertainment center cabinets from a mix of the customer’s cherry and cherry that I provided, while we made the front and back doors from WunderWoods walnut.

Overall, the project is nearly complete (I am finishing up the wine cellar racks), and since I never remember to take photos, I thought it was about time.

Here are some photos I took last time I was there (click on any photo to enlarge and view the slideshow):

The 8′ tall front door is all walnut (plus a little glass).

This wrap-around porch is made of white oak from the property.

The built-in entertainment center (to the right, closed in this picture) and sliding barn door for the office are all made of cherry.

The door to the office is a barn type slider (open, behind TV cabinet), while the doors on the TV cabinet open accordion style to take up less floor space.

The office built-in is all cherry and features reclaimed silo steps (currently kite display) that lead to the loft.

The office built-in houses a second television, also behind accordion-folding doors, like the living room built-in.

The opening is 16′ tall for this walnut back door. The top piece of glass weighs over 500 lbs.

The house has lots of light (and doors).

Special thanks to John Stevens and Dan Draper for their help on many aspects of the job. Also, thanks to Scott Allen and his crew, who took over the general contracting of the house and made sure I always had an extra hand when I needed it.