Case Study: Kerfkore Panels Bring Precision to Chatham Bars Inn Renovation

You never know where you might spot Kefkore panels in the wild. Maybe you’ll see them as a sleek neutral backdrop at an art installation, in the heat of the desert at Burning Man, or in a music performance hall at Texas A&M-Kingsville. 

And if you’re taking a vacation in Cape Cod, stop by the Chatham Bars Inn, where you can find Kerfkore helping keep things running smoothly—right from the shelves at their front bar. 

The Opportunity: Refinishing a Historic Bar 

After more than 40 years of experience in the millwork trade, Ed Shiavo opened his own shop where he specializes in custom woodworking solutions, Ed Shiavo Woodworking, LLC. 

When a refinishing company approached him to help with a project at the bar, Shiavo was tasked with fabricating the custom interior shelving inserts for the bar’s façade and service station. 

After working with Kerfkore in the past, he knew it was the best solution for the job. 

The Challenge: Matching a Curved Façade 

The front bar needed new shelves that would seamlessly integrate with the existing curved bar, along with a new service station. 

Based on his experience, he knew solid wood or bending plywood—also known as wiggle wood—wouldn’t work here. 

“I’ve tried wiggle wood, and it doesn’t keep true to its shape,” said Shiavo. “I’ve used Kerfkore in the past and I’ve always had great results with it.” 

The Solution: Kerfkore’s Reliability in Action 

Shiavo chose to laminate two Kerfkore Soflex panels, each ⅜-inch thick with a particleboard core, to create the shelving inerts. Using forms, he glued and clamped the pieces into shape, then finished them with a white oak veneer. 

“The process was pretty simple and seamless, really,” said Shiavo. “I didn’t have any issues working with Kerfkore. The challenge was making sure everything matched up with the existing façade, but Kerfkore made the fabrication easy.” 

For Shiavo, the standout advantage of Kerfkore is its ability to hold shape without springing back. The reliability gave him the confidence to know the inserts would hold up once installed in the bar. 

The Results: Seamless Integration for a High-End Finish 

The finished shelving inserts fit perfectly into the historic bar’s refreshed look. While Ed’s role focused on fabrication rather than the installation, his craftsmanship and Kerfkore’s dependability ensured the final result lived up to the Chatham Bars Inn’s reputation for timeless luxury. 

You can contact Ed Shiavo at edschiavo.woodwork@gmail.com. For more information about Kerfkore’s Soflex panels, check out the project page, or request a free sample kit today.