FDM - June 2009

FCS recently made 6,000 special doors, starting with a mockup for one unit.

“It had to have an inside reveal, instead of an outside reveal,” says Jess

Lewis. “This is an unusual design. Most of them overlap. We had to make a separate piece. We rabbeted out a shelf on the inside of the stile and rail, then assembled the door as you normally would. After assembly, we would sand the door, then apply trim to the shelf. The trim

would be lower than the stile and rail, thus creating the reveal.”

FCS added a 16-foot
Unique door clamp so they
could have four assembly
stations with 10 pistons. It was
used with Powermatic TS29 slid-
ing table shapers and 3M PUR glue
guns. “Normally, we order doors from a
door company,” Lewis says. “We try to
let people specialize in what they do and
we focus on what we do. But if you can’t
buy them you have to make them.”

Special
door requires
special
fabrication

about 70,000 square feet, with a shop size of about 50,000 square feet. In the woodwork group, 30 to 50 people are employed in the shop, depending on the project, 30 to 50 in the field and 20 people in the office.

“Our biggest challenge is to keep a constant workflow out on the floor,” Holden says.

One of FCS’s biggest projects currently will be visible Sundays this fall. FCS is building private clubs and retail space for the new Dallas Cowboys stadium in Arlington. It doesn’t get any higher profile than that. ●

Paul Holden, vice president, business development, left, and Jess Lewis, woodwork operation manager, right, stand in front of a portrait of longtime FCS president Bill Holden, who is now retired.

For more info
Alliance Millsoft Software
513.542.0740 www.alliancemillsoft.com
Biesse America Selco panel saw, Akron
edgebander
704.357.3131 www.biesseamerica.com
Komo Machine Inc. CNC router
320.252.9887 www.komo.com
Kremlin by Exel Industrial Inc.
Finishing equipment
800.482.1809 www.exelind.com
Microvellum Software
541.664.1625 www.microvellum.com
Powermatic/ WMH Tool Group Shaper
847.851.1000 www.wmhtoolgroup.com
Stiles Shop Solutions Altendorf sliding
table saw
616.698.8456 www.stilesshop.com
TigerStop LLC Positioning system
360.254.0661 www.tigerstop.com
3M Industrial Adhesives & Tape Div.
PUR glue guns
800.362.3550 www.3m.com/industrial
Unique Machine & Tool Co. Door clamp
602. 470.1911 www.uniquemachine.com
Valspar Corp. Finishes
336.802.4732 www.valsparwood.com

Or visit fdmonline.com

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