Keeping History and Heritage Alive
Rose Head Cut Nails and Clinch Nailing
With the advent of screws and the hurried pace of modern industry we are proud to offer you the chance to use genuine rose head cut nails and the technique of clinch nailing in your door assembly.
We source these nails from the oldest nail manufacturer in the country located in New England who has been in business since 1819. They even operate in the original building that had been shelled by the British in the War of 1812!
The technique of clinching a nail ensures nothing will separate board from batton and funny enough is where the saying “dead as a door nail” comes from because once a nail was clinched it was considered “dead” and couldn’t be reused. If you’re looking for historical accuracy and that extra touch to own something totally unique we highly recommend adding this option.
Shou Sugi Ban
Originally developed in Japan in the late 1600’s, Shou Sugi Ban is the process of charring wood and literally translated means “burnt cedar board”. The practice of Shou Sugi Ban was mainly used on residential siding, fencing, and decking projects. This treatment became widely popular for its unique aesthetic appeal as well as the added weatherproofing and resistance to mold and other fungus, but over the last 50-100 years it was slowly replaced and became an all but “lost” technique as wood in Japan had been in short supply and the lower cost of modern plastic and cement based products forced it out of the market.
In the early 2000’s, Shou Sugi Ban was “rediscovered” by architects in Japan and quickly caught the attention of designers in Europe and North America and in just the last couple of years has exploded in popularity for all the same reasons it was so popular for hundreds of years!
When the wood has been charred to just the right point the pores of the wood begin to close and the soft wood is burned off more rapidly than the harder grain giving a weathered raised grain look and a feel that makes you just smile every time you touch it.. Seriously this makes me smile each time I get to do it then run my hand over the finished product. The simple things right.. We have a few different levels of burn and will do a light toast or a deep cook to really bring out the character of the wood and rich chocolate color.
Where do our door names come from?
If you can’t tell already we enjoy sharing history. The names of our doors is just another way we enjoy doing this. We decided to name our doors after historic barn styles crafted to fit their unique environment and intended use throughout the country. We invite you to take a look back and possibly walk away with a deeper appreciation of your door and the inspiration behind it.
The first great barns built in this country were those of the Dutch settlers of the Hudson, Mohawk, and Schoharie valleys in New York State and scattered sections of New Jersey. On the exterior, the most notable feature of the Dutch barn is the broad gable roof, which in early examples (now extremely rare), extended very low to the ground. Barn with a gable roof, central door, and wood siding. A gable roof, center wagon doors with pent roof, stock door at the corners, and horizontal clapboarding are all typical features of the Dutch barn. On the narrow end the Dutch barn features center doors for wagons and a door to the stock aisles on one or both of the side ends. A pent roof (or pentice) over the center doors gave some slight protection from the elements. The siding is typically horizontal, the detailing simple. Few openings other than doors and traditional holes for martins puncture the external wall.
The appearance is of massiveness and simplicity, with the result that Dutch barns seem larger than they actually are. To many observers the heavy interior structural system is the most distinctive aspect of the Dutch barn. Mortised, tenoned, and pegged beams are arranged in “H-shaped” units that recall church interiors, with columned aisles alongside a central space used for threshing among other things. This interior arrangement, more than any other characteristic, links the Dutch barn with its Old World forbears. The end of cross beams projecting through the columns are often rounded to form “tongues” a distinctive feature found only in the Dutch barn.
Relatively few Dutch barns survive today, with most dating back to the late 18th century. Fewer yet survive in good condition, and almost none unaltered. Yet the remaining examples of this barn type still impress with the functional simplicity of their design and evident pride the builders took in their work.
A peak roof projecting above a hayloft opening is one of the most familiar images associated with barns. This feature belongs to the prairie barn, also known as the Western barn. The larger herds associated with agriculture in the West and Southwest required great storage space for hay and feed. Accordingly, prairie barns are on average much larger than the other barns. Long, sweeping roofs, sometimes coming near the ground, mark the prairie barn; the extended roof created great storage space. (Late in the nineteenth century, the adoption of the gambrel roof enlarged the storage capacity of the haymow even more.)
Affinities of this barn type with the Dutch barn are striking: the long, low roof lines, the door in the gable end, and the internal arrangement of stalls in aisles on either side of the central space are all in the tradition of the Dutch barn.
The first barns built in America came from design ideas brought over from England by the colonists. These were simple, open structures built with timber-frame construction. Often windowless, English barns usually had the entrance doors along the eaves and did not have any basement or loft space.
Born out of feudal community spaces in medieval Europe, the designs of the colonists were approximately 30 x 40 feet with a “threshing floor” in the center of the barn. This area would be in front of the eave doors, and would be where the farmer harvested his wheat.
The rest of the barn would be divided into animal stalls and grain storage. English barns were not designed for large-scale agriculture, and the harvesting and storing of grain was their main purpose. The average farmer of the 1700 to 1800s did not have herds of livestock, and needed only a few stables for the family cows and workhorses.
The tobacco barn was once an essential ingredient in the process of air-curing tobacco. Today they are fast disappearing from the landscape in places they were once ubiquitous with the decline of the tobacco industry as states actively discouraging tobacco farming. Tobacco barns were as unique as each area in which they were erected with designs that varied greatly.
Design elements which were common include: gabled roofs, frame construction, and some system of ventilation. The venting can appear in different incarnations but commonly hinges would be attached to some of the cladding boards, so that they could be opened. Often the venting system would be more elaborate, including a roof ventilation system. In addition, tobacco barns do cross over into other barn styles of their day. Some common types of barn designs integrated into tobacco barns include, English barns and bank barns.
The vents are used to slow the drying process down which allows for a critical chemical break down to occur, turning the leaf from green to yellow to brown. To maintain ideal curing temperatures over the course of the curing process, farmers not only rely on the vents, but on heat. While charcoal fires have been replaced in many barns with propane heaters, both methods help reduce moisture. With all of the variables that can impact the curing process, it’s no wonder that the unique design of the tobacco barn has remained constant as a time-tested method for drying tobacco.
After the harvest and while still on the cob, corn is placed in the crib either with or without the husk. The typical corn crib has slats in its walls to allow air to circulate through the corn, both allowing it to dry initially and helping it stay dry. The slats expose the corn to pests, so corn cribs are elevated beyond the reach of rodents.
Corn cribs were first used by Native Americans and were quickly adopted by European settlers. Struggling European settlers often raided corn cribs for food. As a result, at least some Native groups abandoned the corn crib and buried food in caches.
Corn crib designs vary greatly. They were originally made of wood, but other materials such as concrete have also been used. The basic corn crib consists of a roofed bin elevated on posts. Another typical early American design has walls slanted outward. Most of the larger designs have an open space in the middle for accessing corn and promoting airflow. In larger designs, this space was often used to store wagons. By the early 20th century, the term “corn crib” was applied to large barns that contained many individual bins of corn. Today a typical corn crib on many farms is a cylindrical cage of galvanized wire fencing covered by a metal roof formed of corrugated galvanised iron.