Custom Architectural Fabrication for East Troy Home Remodel

Scherrer Construction reached out by phone to ask if we could take on a custom residential welding project that was unlike anything we had done before. They were looking for help on a high-end remodel involving a solid aluminum pocket door, a brass laundry cart frame with a CNC-cut brass shelf, and an intricate decorative handrail system for a concrete interior staircase. After hearing the request, we scheduled a site visit to meet with both the contractor and homeowner to gather measurements and talk through the design needs in person.

On-Site Meeting and Observations

Once on location, we met with the general contractor and the homeowner to discuss the ideas in more detail. It became clear right away that the homeowner had a strong artistic direction and was focused on creating something truly unique.

She had specific materials, finishes, and design features in mind, and every part of the project needed to reflect that vision. We field-measured each area and started sketching ideas on the spot, knowing the work would require a combination of custom machining and detailed on-site fabrication.

Custom Pocket Door Fabrication

The homeowner had a very specific artistic vision and wanted the pocket door to feel like a design element, not just a functional feature. She requested a solid aluminum door where only the top half could open. We got to work designing custom horizontal bar artwork, which was CNC machined and integrated into the door. From there, we fabricated the door frame and hinges for the swing-top section and completed the rest of the spindle body. She chose a flat powder coat finish in a custom-selected color to complete the look.

On-Site Decorative Handrail Build

The staircase and second-floor walkway required a detailed and highly customized handrail. The homeowner wanted no visible legs and asked that the handrail appear to float off the concrete stairs. We started by fabricating three custom mounting pads per step with machined threads to accept concrete studs. These were placed before the staircase was poured.

After the concrete work was finished, we fabricated and installed spindles with pear-shaped finals, welding each one to its designated pad on-site. The top cap was then placed and welded to the spindles, followed by the decorative loop section that connected the first and second floors. Once everything was in place, we prepped the rail for painting with a full weld, sanding, and cleanup.

Brass Laundry Cart Components

While the carpenters built the wooden portion of the laundry cart, we created the custom brass features. This included fabricating brass sleeves beneath the quartz countertop to receive threaded brass uprights. We also CNC-cut a decorative brass top shelf, which was installed above the uprights to complete the cart’s look and function.

Long-Term Project with a Custom Finish

Over the span of two and a half years, we worked in stages as other trades completed their work. Every step of the job required close coordination, detailed metalwork, and on-site fabrication. The homeowner was thrilled when everything came together, saying the final look matched the vision she had from the start.

This project shows what R.C. Portable Welding & Fabrication can do when metal fabrication needs to be both functional and artistic. Whether the job is straightforward or highly customized, we build exactly what’s needed—start to finish.

Looking for Custom Metal Fabrication?

If you’re working on a project that calls for one-of-a-kind and custom metalwork, we can help. From decorative railings to precision-cut doors and custom-built frames, we’re ready to bring your ideas to life.

Give us a call or send a message to talk through your vision. We’ll meet you on-site, take the right measurements, and start building exactly what you need. No matter how detailed or specific the request, we have the tools and experience to make it happen.