Each one of our very popular large (32" high x 24" wide) frames takes around 30 hours to complete. The process begins by sourcing the material at a hardwood lumber supplier about an hour out of town that has been in operation since the 1980s.
They have a large selection of spectacular domestic, exotic and tropical hardwoods from all over the world. Inventory is examined, taking great care to locate the most suitable rough board from which to craft the frame.
This is achieved by carefully inspecting the lumber to limit many common, naturally-occurring imperfections in milled lumber including bowing, twisting and cupping as well as knots, cracks and other blemishes that may require removal of significant portions of the material to eliminate or correct.
The purpose of the inspection process is to ensure there is sufficient usable material that the frame can be made from a single piece of wood so that the color, grain pattern, density, durability and general aesthetics are consistent throughout the entire frame.
Once the ideal piece is selected, the rough board, which is typically about 10-11 feet long, 8-10 inches wide, and around a solid inch-and-a-half thick, is brought back to our shop where work is commenced dimensioning (straightening, flattening, squaring, etc.) the rough wood. During this stage, surfaces marred during the milling process are smoothed and leveled out using both commercial machinery as well as hand tools.
Edges of the board are rendered perpendicular (90°) to the faces, and the board is planed to achieve a thickness that is consistent throughout its full length. Upon completion of this stage, the beauty of the grain and the vibrant colors concealed beneath the raw exterior of the wood are revealed.
Seeing the wood for the first time in its beautified state is one of the most rewarding parts of the process. It's like unwrapping a gift and being overjoyed the moment you set your eyes upon it.
Next, the board is ripped/cut to our standard large frame width of 2.75 inches. The wood is then thoroughly sanded on all sides utilizing a sequence of different grit profiles so that, when done, all sides are nearly as smooth as glass.
From there, the wood is cut into its component parts, which are then precisely mitered at 45° at all ends, rabbeted along their length and assembled using professional joinery techniques. Measurements are taken with accuracy to 1/64th of an inch.
Two splines are then installed at each of the four corners of the frame for lasting durability as well as aesthetics. The splines add a beautiful and unique touch!
The wood species of the splines depend on the wood species chosen for the frame. Splines are added in a wood species/color that is different from, and typically opposes, the species/color of the frame so there is a visible contrast between the two.
If you prefer splines of a particular color to complement your selection of wood frame, we are more than happy to customize these to your liking. Our goal is for you to be in love with your unique piece.
Once the outer frame is assembled, the inner frame is built to the precise size required to achieve a 2.5 inch reveal between the inner and outer frames. A large handmade wood cross measuring 15.75" x 11.5" is added to the center of the frame and a crucifix is selected to adorn the wood cross.
While we prefer our pieces to include the crucifix, it is optional and entirely up to you. Each frame on our site has photos both with and without a crucifix. A groove is then cut for the glass, which is installed at a later point in the process. The glass is high quality, non-yellowing glass ordered from an art gallery in Knoxville and is custom cut specifically for TCD frames.
Fabrics and Amate selections are chosen by TCD's chief designer, or by the buyer in the case of a custom order. Once all options are decided upon, the design is finalized and frame assembly completed.
Any hardware used in the process, such as screws or pins, are of the highest quality, including stainless steel, to ensure the highest quality and durability.
Bearing in mind that this is only a synopsis of the amount of work that goes into making one of our large frames, suffice it to say, the process is extensive and requires tremendous attention to detail throughout every step.
Each of the dozens of options offered has been created with love, patience and reverence, being ever mindful of the scripture, biblical reference or sentiment to which each piece is devoted, and especially to the overall mission of TCD: the Glorification of God.
