The Fabrication Process
We include you in each step of our process, including fabrication. We ask that you give final approval, disconnect plumbing, and remove old countertops.
How custom countertop fabrication works at our Hudson WI facility
The transformation of a raw stone slab into a finished surface is a highly technical process that relies on a combination of digital precision and traditional craftsmanship. At Gallery 77, we perform all stone preparation at our onsite fabrication facility. This local control is a significant advantage for our customers, as it allows us to oversee every nuance of the cutting, shaping, and polishing stages without the risks associated with third-party outsourcing. By utilizing top-of-the-line CNC (Computer Numerical Control) machinery, we can produce countertops of virtually any size or complexity, ensuring that the final product integrates seamlessly into your kitchen or bathroom.
The transition from selection to production begins only after a specialized technician has completed a digital laser template of your space. This digital file captures the exact location of stovetops, sinks, and faucets, and verifies that all cutouts will fit within your specific cabinet openings. This data is fed directly into our computerized cutting systems to achieve absolute precision. To ensure the final result aligns with your vision, we offer every client the opportunity to give final approval on the material’s color, grain orientation, and layout before the first cut is made. This is especially vital when working with Quartzite and Marble, where natural veining patterns can vary significantly across a single slab.
Managing the entire fabrication lifecycle internally allows us to maintain the highest standards for environmentally friendly practices and quality control. Whether you are a homeowner seeking a unique luxury bathroom refresh or a contractor needing consistent results for a commercial build, our onsite process eliminates common industry “surprises.” Our team’s two decades of experience ensure that every edge is hand-finished and every surface is inspected for structural integrity, providing a foundation for a countertop that is as durable as it is beautiful.
Detailed insights into the stone fabrication and template process
Why must my cabinets and farm sinks be installed before the fabrication process begins?
Countertop fabrication is an “exact science” that requires a static environment. We cannot commence work until your base cabinets are permanently secured and leveled. Furthermore, all farm sinks must be installed in their final position prior to the template date. This is because these heavy fixtures dictate the exact starting point for our measurements. Any movement in the cabinets or sink after the laser template is taken will result in an improper fit, potentially leading to costly material waste. This precision is what defines the hallmarks of an honest contractor
What is the benefit of a layout approval session at the fabrication shop?
For materials with high movement or dramatic veining, such as natural granite or Sintered Stone, the layout approval is an actionable step that puts you in the designer’s seat. During this session, we show you how the digital templates for your kitchen island or perimeter counters will sit on the physical slab. This allows you to choose which parts of the stone’s pattern you want to highlight and where the seams will be least visible. While you can choose to forego this step, we prefer it to ensure that the “heart” of the stone is exactly where you envisioned it.
How do access routes and slab weight affect the fabrication of large islands?
When designing a large, seamless island, we must consider the physical limitations of the installation site. Extremely large single pieces of stone are not only heavy but require a clear, wide access route into the home. During the template phase, our technician evaluates your hallways, doorways, and stairs. If the access route is too narrow or has tight turns, we may need to fabricate the countertop in multiple pieces with a professional seam. This ensures the safety of our crew and prevents damage to your walls and newly installed cabinets.
What modern technology is used to ensure my sink and faucet holes are perfect?
We utilize state-of-the-art CNC machinery that reads the digital files created during your laser template. This technology allows us to cut sink openings and drill faucet holes with a level of accuracy that hand-cutting cannot match. It also ensures that the “reveal” of your undermount sink is perfectly consistent around the entire perimeter. This level of precision in countertop installation is why we require all faucets and sinks to be on-site and available for the technician to measure during the template appointment.
How does onsite fabrication improve the quality of countertop edges and seams?
By controlling the environment in our Hudson facility, we can use specialized water-cooled. This allows us to create perfectly finished edges or complex profiles that are consistent across the entire project. Additionally, it allows us to pre-fit sections of your countertop to check the tightness of the seams before they ever leave our shop. If you are comparing Granite vs. Quartz, this onsite control ensures that regardless of the material’s hardness, the finish is flawless.
What specific preparations are required from the homeowner before the fabrication is finished?
While our team handles the technical fabrication, we require homeowners to ensure all plumbing is disconnected in the project area before our installers arrive. We also ask that old countertops be removed unless you have specifically contracted Gallery 77 to perform the tear-out as part of your estimate. Ensuring a clean, level surface for the new stone is vital. If you are preparing for holiday renovations, please communicate any specific deadlines early so we can align our fabrication schedule with your plumbing and electrical contractors.
Ready to see your design come to life?
Contact us today to schedule your template appointment or to visit our facility. You can also explore our gallery to see the precision of our onsite fabrication in person.
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Discover the Gallery 77 Difference
At Gallery 77, we're not just about countertops; we're about turning your living space into something truly extraordinary. Your home should be a reflection of your unique style and personality, and we're here to make that a reality.
We understand that creating a dream space involves more than just picking materials. It's about education, relationships, and exceptional design. Our commitment to you goes beyond the surface. Here's a glimpse of what sets us apart:
Education
Knowledge is the foundation of every great project. Our dedicated team will guide you through the intricacies of materials, products, and design possibilities. We want you to leave our consultations not just inspired but also informed, with a deeper understanding of how to make your space truly remarkable.
Relationships
We believe in the power of strong client relationships. Our transparent approach and commitment to communication ensure that you are always in the loop. We're here to build trust and ensure that both parties have a clear understanding of project expectations and timelines, eliminating any surprises along the way.
Design
With over two decades of experience, we're experts at crafting stunning designs for every corner of your home, from kitchens and bathrooms to outdoor spaces. We stay at the forefront of design trends and technology to create spaces that are not only beautiful but also highly functional.
Curious to learn more about how Gallery 77 can transform your living space into a true masterpiece?
Read more about our philosophy and services. Your dream home is just a click away.
The Fabrication Process at Gallery 77
Why Onsite Fabrication Matters