In The Meantime........
.........I took a trip last week to
Liles Cut Stone...
...in Solsberry, Indiana.
http://liles-cut-stone.solsberry.in.amfibi.directory/us/c/1107515-liles-cut-stone.
These are the nice folks who will be supplying all the limestone window sills and...
...looking at the house plans you can see I've designed
port cochère (that's a high falutin word for
"a covered entrance large enough for vehicles to pass through") over the front door.
The front door will be 6 panel solid door, side lights and a transom with arched limestone trim.
Here is Liles chief designer, Kent Todd. It will be his job to translate my simple door trim design...
...into what I hope to be...
...an interesting focal point. This is a proposed end view of the trim.
They will profile the limestone trim using...
...carbide knives like these with the appropriate profile. Shown are two knives, stacked one on top of the other and my hand to give an idea of scale. The cutting edge with a profile is on the left and right ends of each knife.
The correct knives will be installed in a planer...
...seen here. In the center is a moving 20' long bed that the limestone is secured to. The planer head is lower into the limestone...
...and then with the knife in contact with the stone...
... the moving table moves forward, scraping the limestone under and along the blade edge. Shallow passes are made until the knife makes full contact resulting in the desired profile. In this case it's a straight edge producing a cap stone that looks like...
...this when done. Limestone is soft, so with light passes, there is not much heat build up in the knife blade. Here are some other examples of planer work...
The limestone arrives from the quarry...
...in large blocks.
The blocks are sawn...
...with 3 phase electrical powered saws. Note all the cooling fins on the motor outer casing. Water is flooded into the saw blade while it's cutting. That helps lubricate the blade, carries away cut material and reduces dust. This is a 24" diameter saw.
For larger material they use this 4' diameter saw. When these saws are in action the is just a bit of a loud hum in the shop. We could talk over the noise easily.
The soft-spoken gentleman seen on the far left is
Albert Lile, the owner of
Liles Cut Stone and just about the nicest person you could meet. His shop was neat, tidy, well organized and all the equipment well maintained. Pride in workmanship was evident everywhere and with every employee I spoke with. My kind of folks!
For more complex designs they use this CNC, Computer Numerical Control cutter. That's a block of limestone in the center being cut.
This is the CNC controls.
The CNC utilizes high pressure water jets to cut the stone.
There is still a place for hand work. This is Mike and anything too complex for a machine to make, Mike carves the stone by hand with a pneumatic power cutter and grinders. The wood stove in the background is how Mike heats his little space and it did a great job I might add!
This is some of Mike's tools. To my left is a mighty large drill and behind me are some of his patterns on the shelves.
Founded in 1992 Liles is growing every year. They are constructing an even larger facility behind the existing shop. I'm glad I took the time to visit in person. From everyone I met to the quality products I observed, I know I'll be more than pleased with their work. Once my order is filled I'll go back in a few weeks with a trailer in tow and pick it all up and bring it back to The Center Of The Universe. I'm really looking forward to having Liles limestone incorporated into my home.
More to come, stand by!
Thomas