A renovation tale, Part 2: Demo Day(s)

In Part 1 of this story, you heard about the lead-up to the kitchen reno I’ve been working on at home, and the ups and downs that come with being a professional cabinetmaker overhauling my own kitchen. 

After working on so many awesome kitchens for clients, I wanted to have an amazing kitchen at home, too. So my wife and I had to put ourselves in the shoes of clients and find our way to a design we could agree on. Once we got all of our ducks in a row, it was time for that made-oh-so-famous-by-HGTV step in the reno: Demo Day. 

Or, in my case, Demo Days. 

Because one of our dogs can’t stand loud noises, we had decided that I’d skip a vacation with extended family over Labor Day weekend last fall and take care of the demo while my wife and the dogs were away. 

I’d finished the new cabinets in August, and I was ready to get rolling. 

My own worst enemy  

The kitchen we’re replacing was a DIY project that I tackled before starting Dark Horse (you can find more details about that in Part 1). For an amateur job, it was fine and served us well for 15 years. All in all, I couldn’t complain about my first big kitchen project. 

But when I started in on the demo, I began to feel differently. 

I’m glad there were no TV crews on hand for the Dehmer Demo because it turned out to be a lot more complicated and frustrating than swinging a sledgehammer. I had some unprintable thoughts about the job that Amateur-DIY Chris did on installing that kitchen. 

It sucked. In a word, it was overbuilt. The fact that I built it in place meant that the entire kitchen was basically one big cabinet (the cabinet makers who are reading this will instantly understand the problem this creates for dismantling a kitchen). 

As I wrestled with those cabinets, I thought about how we do things at Dark Horse now and cursed my overzealous ways. In spots where one screw would have been fine, I had used five. It was mind-boggling. 

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In this photo (taken as installation of the new cabinets got under way), you can see a piece of an original wall cabinet that was particularly stubborn.

In the end, I had to cut the cabinets off the wall, and demo took every bit of the two and a half days I had. In addition to the hard physical labor it required to get the cabinets out, demo-ing the floors turned out to be labor-intensive, too – pulling up each board and getting the nails out was no fun. 

All that is to say: While I understand that smashing up a house pre-reno makes for great TV, it’s really not much fun, especially when you find yourself doing battle with the younger, less savvy, more meticulous version of yourself. 

And then there was none

Anyone who’s gone through a kitchen reno is familiar with the work-arounds you have to resort to in the post-demo phase, and we used them all – eating out, ordering take-out, making good use of our grill and (of course) washing dishes in the bathroom sink.

when the dog gets into take out trash

When your renovation work-around strategy consists of eating a lot of take-out meals, we recommend dog-proofing your trash can … just saying.

Meanwhile, we were dealing with all of the bumps in the road that come with actually installing the new kitchen … delays, last-minute changes, trying to get on the same page about all of the big and little decisions you’re faced with in real time. (Didn’t we make all these decisions during the design and planning phase?? you both think every single day.)

Even someone who does this for a living can’t sidestep issues cropping up unexpectedly, not to mention those moments of decision paralysis (for us, it was the paint color for the walls) or last-minute inspiration. 

My 11th-hour decision to use Blum Servo Drive to open all the drawers required a fair amount of work that would have been much easier if planned for up front. (Servo Drive is an “electric motion support system” that allows you to open and close drawers just by tapping them.)  

Once the floors were finally finished, it was a bit of a free-for-all for awhile, and then we got back to following the usual rules of a kitchen installation. 

Cabinets went in, followed by counter tops. Once the counters were in, appliances were installed, plumbing was hooked up and the final electrical work was done. All of that happened in about three days once the tops were in. 

Then it became a matter of tying up loose ends: Moving some lighting, building and installing one last cabinet once the rest were installed and a little trim work. (Some of these loose ends are still loose!) We also had to complete some other reno tasks in the laundry room and sunroom – these spaces became part of the kitchen reno only because the flooring needed to be extended into those rooms so it would all match.

Light at the end of the tunnel

In the final post, I’ll show you the finished kitchen and tell you more about what went into it (literally) – cabinets, appliances, floors, backsplash, hardware, etc.

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Early days of installing the new cabinets

To close out this post about the messiest part of the project, I’ll leave you with this bit of perspective/advice about creating or renovating a kitchen: Just go for it. Get what you want. 

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For our reno story, the Blum Servo Drive system was the major “go for it” feature. We had talked over and over again about how much we’d love to have it in our kitchen, but we always ruled it out because of cost (about $2,600). At some point during our reno, I was talking to a client and making my usual soapbox speech about all the reasons not to skimp, and I realized I was ignoring my own advice.

While I understand that budgets matter, I recommend that you think about the big picture. The kitchen is the most-used room in your house: Don’t compromise.

Postscript: We love our touch-to-open drawers and doors, and we have no regrets about adding them to our budget.

~ Chris Dehmer

Chris Dehmer elected VP of Cabinet Makers Association Board

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New CMA VP Chris Dehmer with Matt Krig, former CMA president and fellow CMA board member, at last summer’s AWFS (Association of Woodworking and Furnishing Suppliers) Fair in Las Vegas. 

After serving two years as an at-large member on the Board of Directors of the Cabinet Makers Association (CMA), Dark Horse Woodworks’ Chris Dehmer has been elected vice president of the industry group for professional cabinet makers and woodworkers in the United States and Canada.

The CMA describes itself as a professional organization “where cabinetmakers and woodworkers from both the residential and commercial markets get together and share their hard earned knowledge and experience to help one another.” 

Chris joins new president Leland Thomasset, treasurer James Fox and secretary Monika Soos.

“Being a board member has opened up new communication lines with other board members,” Chris says. “It really has taken my involvement to a whole new level.” He points to a visit that he and former CMA president Matt Krig made to Thomasset’s workshop in Maine when they were in the area for a regional event. Their idea was to take advantage of being nearby to have a hands-on working visit with Thomasset.

 “We showed up in work clothes and were able to work on a project and see how Leland’s shop works, get ideas from him and offer ideas from our own shops,” he says.

FDMC magazine even ran a feature about the collaboration. 

“Being on this board has changed me and my business forever,” Chris adds. “Being a member of the CMA was great, but being a board member forces you to be involved – and being involved is the only way to get maximum return on membership. 

“Without my board experience, I probably wouldn’t have agreed to be a part of the CMA shop tours this coming August when the International Woodworking Fair comes to Atlanta,” he says. “Before, pride and ego would have gotten in the way. Now I’m inviting people to come on the CMA tour and tell me what we’re doing wrong. It’s great to be part of a group that allows me to get to know people who are so generous with their time, experience and expertise.

“My involvement with the CMA is the single best professional development opportunity I’ve ever encountered, and I’m happy to take on a new role this year.”

You really do get what you pay for

I recently had the eye-opening experience of seeing some high-end homes that had surprisingly low-end cabinetry. While many of the cabinets looked nice when you glanced at them with the doors shut, you only had to inspect them a bit more closely to figure out that the materials and construction were not exactly top-of-the-line.

Frankly, it was a shocker.

How did such shoddy work end up in such exclusive, expensive projects?

When you’re in a craft profession, this kind of thing can be frustrating.

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We’re grateful to have gained the trust of clients who have hired us to create their dream kitchens and other projects; this is the project we call “The Walnut House.”

Knowledge matters

Coming across this less-than-impressive work in otherwise well-crafted, big-budget homes made me stop and think about how these decisions are made.

Do the homeowners just not worry about the details that make the difference between a high-quality project and a shoddy one? Or do they not know? 

For those who are considering a remodel or new construction, I thought I’d pass along some insider perspective based on the Dark Horse approach to custom cabinetry.

First, it’s my experience that while clients know the big picture of what they want (style, color, etc.), they almost never tell you what they want when it comes to materials and construction.

For that reason (and many more), we have a spec sheet that we share with potential clients that outlines the type of materials we use. We’re careful to say, “This is what you’re getting.”

Our specs are identical 99 percent of the time; we never approach a potential job with the idea that we’ll customize our specs and use lower-quality, cheaper materials in order to give Dark Horse a better chance of winning a bid.

We’ve built our reputation on executing client projects the best way we know how, and in addition to the level of craftsmanship we offer, we make a point of seeking out the best products and materials available.

Here are a few examples:

  • Every cabinet box we build is two-sided, pre-finished and US-sourced.Why US-sourced? Once, we tried cheaper Chinese import plywood for some shop projects; when we cut the material, it smelled funny, and the sawdust from the cut was blue. Consistency in thickness is more critical than ever since we incorporated a CNC into our production – we have to tell the machine how thick the material is so that the joints come out tight. Domestic plywood tends to be much flatter – I’m not sure why this is but my guess is that it has something to do with the imported plywood sitting on a ship during transport.

    To give you an idea of the difference in materials, the domestic plywood we use costs $65-70 a sheet; some companies use particleboard that costs $18 per sheet (similar to what you see in IKEA furniture).

  • We don’t use prefab drawers, and that makes a huge difference in both looks and function.
  • We also use Zero Edge banding on our cabinetry, which is more heat- and moisture-resistant than typical edge treatments. But that advantage comes at a price – 80 cents per foot instead of 2 cents per foot for traditional hot glue edge-banding.
  • We use soft-close doors, slides, etc. – in short, the best hardware we can buy. It costs a little more, but it’s worth it. (There’s a lot of cheap, shoddy hardware out there.)

 

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Here’s an in-process photo showing the kind of 3/4-inch prefinished plywood cabinet box construction that goes into all of our projects; this happens to be my own kitchen, which my wife and I decided to renovate last year. (There’s no top because this is a sink cabinet.)

 

What’s the lesson you can take away from this insider view?

You get what you pay for.

A company with a solid reputation and happy customers obviously excels at the craft of cabinet-making, but that company also begins with high-quality materials, and those materials cost more. (I have yet to find a magical source of stellar materials at bargain basement prices, but if you have any leads, I’d love to hear about them.)

Our Golden Rule

Some companies have the advantage of a showroom where clients can see examples of their work; that would be a great way to show our clients what quality materials and craftsmanship look like, but a showroom is not an option for Dark Horse.

So instead, we just try to emphasize to clients what we choose to use in our work and why we choose it.

And the “why” is simple – it’s the way I would want it done in my house. If I wouldn’t put it in mine, I won’t put it in yours.

~ Chris Dehmer

A renovation tale: Shoes for the cobbler’s children (Part 1)

In this modern version, I’m the cobbler, and it’s way past time for me to build a new kitchen at my house.

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Our first kitchen reno – pre-Dark Horse

I’m pretty sure it’s impossible to build dream kitchens for clients year after year and not want to create your version of the ideal kitchen.

Long ago, about six years before chucking my day job and starting Dark Horse, I renovated our kitchen on my own. When we’d moved into our Craftsman-style house, the kitchen was tiny, maybe 10×10. It had a sink and a refrigerator, and that was it. The original giant cast iron sink was rusted and not very practical. The metal cabinets were not deep enough to hold modern dinner plates, and there was no stove or oven.

Kitchen Before

When we first bought our house, this was the state of affairs in the kitchen.

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And another view; this kitchen is a cabinetmaker’s nightmare.

The renovation I did as an amateur with some solid skills was fine – and it was certainly a huge step up from what we started with. The style we went with then was traditional, and the kitchen has served us well.

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But about three years ago, I reached the point where I had to do something with all of that inspiration I’d been getting from my Dark Horse work. While there was nothing wrong with our kitchen, it was not what I’d call “awesome” – and I wanted to come home to a truly awesome kitchen.

My wife and I were on the same page, and the decision was made.

Getting started

There’s no doubt that there are advantages to being a professional when you’re doing a personal kitchen reno project. But I’ve learned firsthand that there are some hurdles you can’t escape whether you’re an amateur or a pro, and other things that become more complex because you do this stuff for a living.

For instance, I quickly figured out that when the goal is agreeing on a design and making all the other decisions that have to be made, having professional expertise in the mix can complicate matters instead of speeding them along.

Most couples setting out on a renovation are starting from the same place, after all, learning as they go.

The unique challenge for my wife and me was the fact that we brought two very different perspectives and sets of experience to the table. Because I do this for a living, I have what is probably an excruciating amount of knowledge about everything that’s involved. On top of that, building kitchens for a living also means that I have strong preferences.

To sum up what I mean, picture this not-so-imaginary scene: My wife rolls her eyes as I explain why we must have XYZ feature/material/hardware in the new kitchen. Minutes later, I throw my hands up because she just doesn’t appreciate the great wisdom I’m bringing to the process. Repeat scene – many times.

Beyond the difference in perspectives, doing your own renovation also makes you appreciate the ease of working with clients on a kitchen that isn’t yours.

I have many conversations with clients about what their dream kitchens will look like, and I now recognize what a breeze this part of the process is for me. During the planning and design step, I get to lay out the options, explain the basics and then exit the process. The clients go away and hash things out, and we meet again to finalize everything.

When it’s your kitchen, you can’t step away from the process and let other people make the decisions. You have the same challenge as all of your clients who are doing a renovation with a partner: You have to work through it all with the other person, make a case for your (strong) preferences and end up as close to mutual satisfaction and civility as possible.

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Another shot of the first kitchen I installed; it’s all gone now.

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Desk area included in our original reno kitchen

Finding common ground

So how did we get through the decision-making phase?

My wife had been looking at a website called Houzz since we first started talking about the project three years ago.

In case you’re not familiar with Houzz, the short version is that it’s a website filled with home design ideas, photos of real-world, finished projects, vendor pages and a lot more. Dark Horse and pretty much any other company involved in building or renovating homes have a presence on Houzz because so many homeowners go there to search for ideas. Houzz turned out to be the main driver for my wife to figure out what she liked.

My past projects were a big source of inspiration for me, of course, and I knew from the start that I wanted to move away from the traditional look of our current kitchen. I liked some aspects of the modern kitchens that have become our specialty at Dark Horse.

At some point along the way, I spotted a kitchen I really liked in my wife’s saved projects on Houzz. I had never seen a style quite like it, and I’m sure that’s what caught my attention. By the time this kitchen entered the picture, we were on about version 6 of our project design attempts; the fact that we both liked this one was big, and we knew we needed to run with it.

There were still compromises to be made along the way, of course – for instance, my wife wanted painted cabinets, and I preferred wood grain. In this case, I decided not to push my preference since the overall design was something I liked.

Chance encounters

On top of the challenge of getting on the same design page, we also experienced another common renovation struggle: Getting to the starting line.

Building other people’s cabinetry for many hours a day can certainly take a toll on your personal renovation plans, and even the goal we’d picked as an incentive ended up being a convenient excuse to delay the project. When we’d decided to go forward with the reno three years ago, our goal was to have it completed before the Dark Horse holiday party that we host in early December every year.

But for the next couple of years, when work projects and personal obligations began to stack up in the months ahead of December, we’d throw in the towel. “Well,” one of us would say, “there’s no way we can get it done before the party now, so we might as well wait.”

In the end, it was a chance encounter that threw the switch on the project at last.

In January 2016, with the latest holiday party behind us and the renovation still not scheduled, I headed to a big industry show in Orlando. While I was checking out new hardware and other products for Dark Horse, I stumbled across some cool retro appliances, and they gave me a new shot of inspiration.

I came home and sent an email to a design team I know and asked them if what I had in mind was up their alley. They sent back an enthusiastic “yes,” and by the end of January, I had sent them a list of the appliances and other things we liked.

Full-steam ahead

By the end of February, the designers had sent us options for finishes, floor tiles, walls, backsplashes, etc.

The style we landed on doesn’t fit neatly into any of the usual categories, so maybe “eclectic” is the best way to describe it. There are modern elements, such as clean lines and minimal door hardware. The raised panels on the doors (kind of a reverse Shaker) give a nod to the Craftsman style of the house, and we added some retro touches via the appliances, tile floor, backsplash and reeded glass doors.

Once we hashed out the design particulars, the project fell into a good rhythm.

In March, we made final decisions on appliances, and by Memorial Day, I had begun building out the cabinetry. Around the first of August, the cabinets were done, and I decided to start demo the week of Labor Day. One of our dogs is petrified by loud noises, and we decided it would be better to have him out of the house; my wife and the dogs headed out of town to join family for a long-planned vacation, and I got ready to dismantle that kitchen I had labored over all those years before.

On HGTV shows, everything I’ve just described takes place in a span of days, not years, and “Demo Day” is a pretty exciting highlight for everyone, with homeowners and TV hosts alike bashing walls and ripping cabinets apart.

In order to keep some suspense and excitement going in my reno story, I’ll wrap up Chapter 1 (“before”) here and begin Chapter 2 (“during”) with the thrills of Demo Day; be sure to tune back in to find out what a Demo Day is like in the real world!

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Celebrating 10 years of Dark Horse Woodworks

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I was tempted to keep this photo to myself, but decided I may as well put it out there, especially since fellow small business owners will relate: That first check was cause for celebration!

In the middle of the holidays, I realized that another important occasion had crept up on me: the 10th anniversary of Dark Horse Woodworks. Our first day of business was December 28, 2007, and like many of my fellow cabinet makers, our first place of business was my garage.

When you go out on an entrepreneurial limb, it’s both exciting and terrifying. Taking my sideline full-time was a risk and a leap of faith, and back then, I wouldn’t have dared think ahead to whether the company would still be around a decade later.

I’m very happy to be one of the people whose leap of faith paid off; big anniversaries like this one are nice because they make you stop long enough to look back and take stock.

A character-building experience

 

There’s no question that running your own business brings plenty of headaches, trial-and-error learning and moments of sheer panic. Even when your venture becomes a success, you go through times when you feel nostalgia for the days when your business was smaller and you had less on your plate.

Some days, success means keeping your sense of humor and perspective intact long enough to avoid crossing that dreaded boundary where the thing you love becomes the thing you dread.

Thankfully, along with all of the challenging times and learning curves, Dark Horse has also seen more than our fair share of high points – positive changes in the business itself, exciting honors and gratifying feedback for our work, and great relationships with peers in the industry.

Bigger space, bigger ideas and a bigger universe

Dark Horse Woodworks’ growing physical footprint may be the most obvious change we’ve seen in the past 10 years. Looking back, the thing that astounds me most is the fact that I built a few kitchens for people in my 400-square-foot garage. Now that I have 6,000 square feet (and wish I had even more), it just seems impossible.

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Early garage shop days…

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A tight squeeze.

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Using every bit of space – vertically and horizontally.

Along with the increase in square footage, we’ve also expanded the technology we have on board, which has enabled us to expand the services and types of cabinetry we can offer. (We’ve written on the blog about our Zero-Edge technology and about the CNC router that we added just this past year.)

We also joined the Cabinet Makers Association (CMA), the association for professional cabinet makers and woodworkers in the United States and Canada. This turned out to be a huge decision for us; after all, at 10 years old, Dark Horse is still a newcomer compared to many CMA member shops that have been around for several decades. I always learn a lot thanks to the generosity of more experienced CMA members.

On top of the relationships and resources, we’ve also been recognized with multiple CMA “Wood Diamond” awards every year since we joined; being recognized this way by our peers is important validation that our work is hitting the highest marks.

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Accepting one of our 1st-place Wood Diamond awards from CMA president Matt Krig in July 2017

A couple of years ago, I was honored to be elected to the board of the CMA, and I always enjoy being part of the regional events, shop tours and trade show activities. In March, I’ll be doing a presentation at the CMA’s 20th Anniversary conference in Denver, and this summer, I’ll be a CMA speaker at the International Woodworking Fair in Atlanta. It’s a good feeling to have gone from being a novice in the cabinetry/small business world to having learned enough to be able to share some often hard-won lessons with others; starting and building Dark Horse has been a little like getting a 10-year business and entrepreneurship degree.

Teamwork

We would never have made it this far without clients, architects, designers and homebuilders who trusted us to team up with them on their projects.

I have some really great clients who have become great friends since we did their projects, and I’m especially appreciative of the folks who hired Dark Horse back in the early days before we had a track record.

And of course, I could never have made the business a success without the people who have worked for me over the course of our first 10 years; thank you for helping Dark Horse deliver quality and workmanship to each of our clients.

Icing on the cake

We would be bad marketers if we didn’t share the good news when our work gets coverage in the media, so if you follow our blog, you may have already read about some of these things.

But marketing aside, seeing your work in a publication or recognized in the community is pretty thrilling on a personal level, so I wanted to mention those kinds of high points in this anniversary post, too:

  • The Friar Tuck project was featured in a New York Times real estate story.
  • The Oakview home was featured in Dwell magazine magazine.
  • I was glancing at Dwell’s website one day and found more of our work in several of their online features.
  • Curbed Atlanta featured a home with a Dark Horse kitchen (created with Zero-Edge technology) in July.
  • Dark Horse was the cover story in the Winter 2017 issue of PROfiles, the CMA magazine.
  • The CMA invited us to participate in a video series in 2017 and gave me a chance to talk about how we got started, why I love what I do and some of the technology that is taking Dark Horse into the future. Feel free to check out the interview (it’s a bit over two minutes long).
  • Our work has also been included on the highly respected (and popular) Modern Atlanta home tour three times.

Thanks to everyone for your support and cheerleading; I’m looking forward to seeing what our next decade brings.

~ Chris Dehmer

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A lucky glimpse of our work on a “mid-century modern treasure”

Screen Shot 2017-08-18 at 4.46.51 PMFor most of our projects, we create cabinetry for multiple rooms in a home, and we end up with extensive photos of the final “product” that we share in our gallery.

For a recent project, we worked on only one room, creating high-gloss kitchen cabinetry with the Zero-Edge technology we invested in last year. In this case, we did not do the installation, which is rare for us. Work is hopping, and I never followed up to get post-installation photos of the finished kitchen.

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Fortunately, this beautiful mid-century modern home went on the market not long ago, and it drew the attention of Curbed Atlanta, which featured the home in July (“In Druid Hills, midcentury modern treasure is ‘unadulterated’ for $799K”).

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It was great to see the finished kitchen, and thanks to the kindness of the staff at Domo Realty, which is handling the sale of the home, I’m able to share screenshots of the kitchen here.

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A view of the kitchen from the dining room

If you enjoy mid-century modern, I highly recommend that you take a look at the Curbed Atlanta feature, as well as the Domo Realty listing for extensive photos of this distinctive home.

And the folks at Domo also passed on a compliment that we appreciated: The house is under contract, and they told us that the kitchen helped sell the house. We enjoy seeing all of our projects through from start to finish, and that kind of feedback is the icing on the cake.

Dark Horse wins four 1st-place awards from the Cabinet Makers Association

I headed to Las Vegas last week for the AWFS (Association of Woodworking and Furnishing Suppliers) Fair, one of the biggest events for our industry. There are always new products to see and great ideas to bring home, and this year, I also got a chance to promote the Cabinet Makers Association (CMA) in my role as a board member.

I enjoyed all of that, but there was another very important highlight of my trip: Four first-place “Wood Diamond” awards from the CMA, which held its awards dinner during AWFS.

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CMA President Matt Krig took time to offer his congratulations for our awards during AWFS

 

As I’ve said before, the awards mean even more because we know our fellow cabinet makers truly “get it” – they look at our work and understand the time and attention to detail we put into it.

So what is a Wood Diamond Award? “The CMA was founded on the principles of sharing one’s experiences and ideas with other members in an effort to promote success and professionalism in the woodworking business,” says the association’s Executive Director, Amanda Conger. “The Wood Diamond Award program allows yet another outlet for that purpose to be fulfilled.”

CMA members who were not participating in the competition served as judges; this year, the awards recognized 34 award winners from 17 member companies.

Here are the details on our awards and the projects that were recognized:

1st place ~ Kitchen: European (Under $25,000)
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1st place ~ Bar, Residential: European ($25,000 – $50,000

Project 36

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1st place ~ Fireplace Surround: European (Under $25,000)
Project 36

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1st place ~ Closet: European (Under $25,000)

Wildwood closet and mudroom

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I’ve said this when we’ve won awards in the past, and it rings true any time our work is recognized. Without design-savvy clients, designers, architects and all of the other talented people we partner with on projects (and their commitment to quality), Dark Horse would not have award-worthy work, so we share this recognition with all of them.

~ Chris Dehmer and the Dark Horse team

Christmas in March

routerphotonewAt Dark Horse, we’ve always had an Old-World emphasis on craftsmanship, quality and attention to detail.

But we don’t believe that having Old-World values means you can’t embrace ways of working that are very much New-World. In our 10 years in business, Dark Horse has experienced first-hand the benefits that great technology and an open mind can bring to our process and to the final product we deliver to clients.

Awhile back, we shared photos of Wildwood, our first big high-gloss kitchen cabinetry project that was made possible by the Zero Edge technology we invested in last year.

In March, we had another red-letter day on the technology front: Our very own, shiny new CNC router was delivered.

For those who aren’t in our line of work, it may be pretty challenging to convey just how exciting this was, but we’ll give it a try.

So what is a CNC router?

Let’s start with CNC.

We found a pretty straightforward definition online at technologystudent.com:

CNC [stands for] Computer Numerical Control. This means a computer converts the design produced by Computer Aided Design software (CAD), into numbers. The numbers can be considered to be the coordinates of a graph, and they control the movement of the cutter. In this way, the computer controls the cutting and shaping of the material.

Dark Horse will now be using a method sometimes called “screen to machine” to cut the parts for our custom cabinets in-house.

We draw the components on a computer screen with design software, which then sends code to the CNC router. The machine takes that data and cuts all of our cabinet parts so that they come off the machine ready to go — all holes for hardware are drilled, etc.

Thanks to the interaction of the software and the machine, the router grabs the right tool for the task at hand, then changes to another tool automatically when needed.

With screen-to-machine production, the possibility of injury is greatly reduced (fingers are on a keyboard, not next to spinning blades), and the accuracy is ridiculously good (1/1000 inch).

To see the router in action, check out this time-lapse video of our new machine cutting trolley signs to be sold by South Atlantans for Neighborhood Development (SAND).

A logistics win

There are many intricacies that this process makes possible – including generating a single file with a unique name for each sheet of material that is going to be cut and a label for each piece.

Basically, once the design is approved, files are sent to our network that tell the machine every operation that is required for the parts on each sheet; in addition, a printout is made for each sheet that has a barcode at the bottom corresponding to the file name of the sheet to be cut.

The operator scans the barcode at the bottom of the page, the machine loads the correct file, and then it begins the process of cutting.

After the cutting is finished, the Dark Horse team can take each piece off of the machine, apply its unique label, and sort the pieces according to the type of edgeband they are going to receive. We can start the edgebanding of those pieces while the next sheet is being cut.

Another member of the team can then begin to put the boxes together as soon as all of the parts for that assembly are made.

Flipping the process

My interest in programming and software has led me to approach decisions about technology investments in an unusual way. Many businesses invest in expensive machinery and then learn how to use the software that makes it run.

At Dark Horse, we’ve always gone in the opposite direction; to me, it doesn’t make much sense to have an expensive machine sitting idle in my shop while my team and I spend time wrapping our heads around how the software works.

So we buy the software first and learn it inside and out through tutorials or videos.

By the time a new machine is delivered, we’re ready to roll. This doesn’t mean we never have questions once we start using it; that’s a given. But those questions are easier to resolve quickly if you have a solid understanding of your software and machinery.

I believe this philosophy has been a major factor in our success. With this machine implementation, we were up and running at full speed as soon as the machine was integrated into our software, which was only one day after the machine installation was complete.

Two months in, we are completing projects that fully utilize our new technology in about one-third of the time we were spending before bringing the CNC on board.

~ Chris Dehmer

Join an industry group for an instant network and plenty of great ideas

 

Habersham3

One of the shop tours organized by the Cabinet Makers Association

If you’re a regular reader of our blog, you know that Dark Horse is a big fan of the Cabinet Makers Association (so much so that I became a board member last year).

The best part of being in this group is the ability to draw on the knowledge of other members; in the grand scheme of things, Dark Horse is a “newcomer” compared to some shops that have been around for several decades, and I always learn a lot thanks to the generosity of others.

And it’s always a great moment when we find that we can offer some wisdom to other shops.

On-call help

The idea for this blog came up when we were putting together a post (we’ll publish it soon) about our new CNC router, a game-changing technology/machinery addition at Dark Horse.

We chose to invest in the software that partners with the router first, and learn our way around that piece of the process before buying the router.

Now that we have the router, and we’re gearing up to put it all together and start cutting our custom cabinetry pieces in the Dark Horse workshop, I have no worries about any questions that are sure to come up in real time and need quick resolution.

Why? Because I know that I can always pick up the phone and call one of my CMA friends who already have a lot of hands-on experience with CNC routers.

As with many situations, your personal network of friends and industry colleagues can often deliver the answers you need even more quickly and effectively than a manufacturer’s customer service “hotline.”

And this advice isn’t just for building industry types … 

When you start a business, it’s tempting to want to go it alone and look at the others in your line of work as competition – even if they aren’t literally vying for the same customers, you may see them as competing against you for awards or respect or reputation.

You’ll miss a lot of opportunities to learn if you think this way.

I highly recommend that you find the equivalent of the Cabinet Makers Association for your industry and join up and be active; with groups like this, you get out what you put in.

I’m looking forward to my next chance to pick up some new ideas in a couple of weeks: Just before one of our big industry events in Chicago, the CMA is sponsoring one of its shop tours so we can check out nearby cabinetry companies.

I’ll be there, looking for ways that Dark Horse can up our game.

Grateful: A quick look back at a year full of opportunity

NYT kitchen

It’s been another great year for Dark Horse, and none of it would have been possible without the faith that our clients place in us when they hire us to help build their dream projects.

Below are a few of the 2016 highlights we featured on our blog over the course of the year; click through to read more details about each story if you’d like.

Thanks to all of our clients, supporters and friends for sending us work and reading our stories over the past year: We wish you all a great 2017.

~Chris and the Dark Horse team

NYT kitchen

April 13, 2016

Dark Horse featured in the New York Times

Our work debuted in the New York Times in the spring!

The Friar Tuck house, a beautiful modern home renovation we worked on a few years back, was on the market, and the Times chose to feature it in its “What You Get” real estate series. Each story in the series features three properties of varying styles in different areas of the country that are for sale in the same price range.

In the story, $1,800,000 Homes in Kentucky, Atlanta and New Mexico,” we were called out for the award-winning kitchen cabinetry in the home.

August 26, 2016

Chris Dehmer elected to Cabinet Makers Association Board of Directors

Chris was honored to be elected to the board of the Cabinet Makers Association (CMA), the association for professional cabinet makers and woodworkers in the United States and Canada.

“Being part of the CMA has given Dark Horse the opportunity to connect with and learn from many stellar wood-working businesses across the US and Canada,” Chris says.

September 1, 2016

Dark Horse wins 5 Awards from the Cabinet Makers Association

You can imagine how excited we were when the CMA recognized Dark Horse with four first-place Wood Diamond awards and one third-place award at the CMA awards ceremony in Atlanta this summer!

The Balmoral project

First place, Euro Kitchen under $25,000 category

The Wesley bar

First place, Residential Bar (European) under $25,000 

The Olympic house 

First place, European Library under $25,000

Third place, European kitchen under $25,000

The Stonehaven project

First place, Mudroom under $25,000

October 5, 2016

Seamless: Dark Horse acquires “Zero-Edge” capabilities

We’ve acquired the technology to produce cabinetry and furniture components with seamless edges. Zero-Edge Technology, as it’s usually called, is a game-changer for our company and the industry as a whole.