Creating an Archway
creating an archway competed archway
Cover the floor with a drop cloth
Use a claw hammer to pry the existing doorjambs from the opening
Cut four short 1x4s to serve as nailing blocks for the new drywall patch
Cut two pieces of drywall
Carefully cut the cardboard out
Remove the columns and cut the elliptical shapes from the drywall pieces
Conceal the new drywall patches with drywall tape and joint compound
Start the final installation by first lifting the elliptical archway into place
Stand the columns under the arch and slip them over the walls

1. Cover the floor with a drop cloth.

Run a utility knife along the joints between the casing and the drywall on both sides of the opening. Use just enough pressure to slice through any paint or caulking. Don't cut too deeply into the drywall. Loosen the casing with a flat pry bar, then pull the pieces off the wall.

2. Use a claw hammer to pry the existing doorjambs from the opening.

Also, remove the baseboard molding from both sides of the opening. Be careful not to damage the walls.

3. Cut four short 1x4s to serve as nailing blocks for the new drywall patch.

Cut two pieces 8 inches long and two others equal to one-third the width of the opening. (For a 4-foot-wide opening, cut the 1x4s 16 inches long.) Nail the shorter 1x4s to the trimmer studs on each side of the opening and fasten the longer ones to the header above.

4. Cut two pieces of drywall 15 inches high and as wide as the opening.

Be sure to use drywall that's the same thickness as the existing drywall (typically ½ inch). Raise the drywall piece into place and secure it to the 1x4 blocking with 1 ½-inch drywall screws. Hang the second drywall piece on the opposite side of the opening.

5. Carefully cut the cardboard out with a utility knife.

The archway kit includes an elliptical template that's part of the cardboard shipping carton. Then, slip the vertical columns into the opening and set the template on top. Use a pencil to scribe the elliptical shape onto the new drywall. Repeat this procedure to mark the drywall on the opposite side.

6. Remove the columns and cut the elliptical shapes from the drywall pieces using a drywall saw.

Follow the pencil lines as closely as possible, but don't worry if your cuts are a little crooked; the arch will hide them.

7. Conceal the new drywall patches with drywall tape and joint compound.

Cover all the seams between the new and old drywall surfaces with either paper tape or adhesive-backed fiberglass-mesh tape. Then finish the joints with two or three coats of joint compound. Allow each coat to dry before applying the next. Lightly sand the patch smooth, then rolled on a coat of primer.

8. Start the final installation by first lifting the elliptical archway into place.

Be sure that it's pushed up as far as possible.

9. Stand the columns under the arch and slip them over the walls.

Pull down on the arch so that it sits tight against the top of the columns. Before nailing the parts in place, be certain that the columns are perfectly plumb and parallel. Also, check to make sure that the ends of the archway are centered on top of the columns. Secure all of the parts with 2 ½-inch finishing nails; bore pilot holes first to prevent splitting.

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June 2008 - Special Reader Issue
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The best interior renovations capture your attention the instant you enter the room—and continue to each time you pass them. It's easy to make a big impact if money isn't an issue. Move a few walls, raise the roof, install larger windows and buy all new furniture. Unfortunately, that's not a very practical solution for most of us. Painting the walls and installing new window treatments are realistic options, but for more dramatic impact, try adding some architectural interest to a room.

In this "Weekend Project," we'll show you how to transform an ordinary rectangular cased opening into a beautiful elliptical archway that features fluted columns and an arched header with keystone accents (see the finished project on the facing page). Architectural woodwork like this involves a high degree of skill, well beyond the capabilities of most homeowners. It's even difficult to find a carpenter who can do this kind of work reasonably. So we cheated by ordering a prefabricated archway kit from Raleigh, North Carolina—based CurveMakers. We were able to complete the installation in only two days.

The archway, milled from paint-grade poplar, consists of only three preassembled parts: two columns and one archway header. Each column is made up of a pair of fluted casings attached to a flat side jamb. A decorative capital molding is attached to the top of each column, and plinth blocks are fastened to their bottoms.

The archway header comes with the curved casings attached to the curved head jamb. There's even a decorative keystone affixed to the center of each head casing. The three preassembled parts are ready to be installed right out of the box; they don't even require sanding.

CurveMakers offers four different models of poplar archway, which range in width from 2 feet ($517) to 8 feet ($1,260) in elliptical and half-round shapes. At an additional cost, you can special-order an archway made out of oak, cherry, mahogany and many other species.

For help on ordering a kit for your room, go to www.curvemakers.com. Click on the "Order" button for complete instructions on how to correctly measure an existing passageway opening. The site also includes color stepgraphs of all the standard kits.

For our room renovation, we chose a 4-foot Model B poplar elliptical-archway kit ($643). The first day we prepared the existing opening; on the second we installed and painted the archway.

As an economical alternative to its standard kits, CurveMakers recently introduced the E-Z Arch kit, which contains only the prefab elliptical header; there are no columns, casings or jambs. Made of medium-density fiberboard, it's also available in widths ranging from 2 feet ($182) to 8 feet ($309).

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