Custom Haunted House Facade for Vintage Works — Faux Granite Look Cornice System Delivered with Perfect Fit & Fast Installation
Project Type: Custom Retail / Themed Commercial Facade
Location: Little Suamico, Wisconsin, USA
Client: Vintage Works
Industry: Retail / Experiential Design / Custom Build
Product System: Custom EPS Cornice Trim + Hardcoat Finish by Royal Foam
Timeline: Custom fabrication + delivery on project schedule
Result: Royal Foam supplied a highly detailed custom cornice system that visually matched surrounding granite, solved a difficult 16-inch façade gap, and installed with exceptional ease.
PROJECT OVERVIEW
Vintage Works created a remarkable new storefront concept that transitions from an English-style storefront at ground level into a dramatic haunted house-inspired upper façade.
The project included:
- Custom-cut granite stonework
- Fantasy architectural styling
- A jet turbine intake transformed into a robot chest feature
- Ornamental detailing requiring precision fitment
One major challenge remained:
A 16-inch-tall gap between the top of the granite stone façade and the roof soffit required a custom cornice trim with exceptional detail.
After searching extensively, Vintage Works selected Royal Foam to engineer and fabricate the perfect solution.
THE CHALLENGE
Context
- One-of-a-kind branded storefront design
- High-visibility retail destination
- Complex mixed-style architecture
Constraints
- 16" vertical gap requiring custom trim
- Existing granite dimensions already installed
- Need for perfect mitered corners and visual continuity
Risks
- Generic trim would look low-end
- Stone alternatives would be expensive and heavy
- Poor fitment would compromise design intent
- Long custom fabrication timelines could delay opening
THE SOLUTION (ENGINEERING APPROACH)
Material System
- High-density EPS architectural trim core
- Stucco hardcoat finish system
- Sherwin-Williams premium exterior paint for final color integration
Structural System
- Lightweight installation-friendly profile
- Precision-cut lengths
- Contractor-friendly mounting process
Fabrication
- Existing Royal Foam profile modified to exact customer dimensions
- Corbels repositioned to align with project geometry
- Clean miter-ready corners for seamless installation
Customization
Royal Foam tailored the design to provide:
- Correct height for 16" gap
- Perfect corner alignment
- Matching period style detail
- Stone-like appearance beside granite façade
Result: A premium custom solution without custom-stone cost or weight.
SYSTEM ARCHITECTURE
Component Build-Up
- Precision EPS profile core
- Stucco hardcoat exterior shell
- Premium finish
- High quality exterior paint
- Easy-install mounting interface
Result: Rich ornamental detail with lightweight handling.
BEFORE / AFTER COMPARISON
BEFORE
- Open 16" gap between stone and soffit
- Incomplete façade line
- Risk of mismatched trim quality
AFTER
- Finished high-detail cornice crown
- Seamless transition between stone and roofline
- Authentic haunted-house architectural presence
Visitors now experience a complete immersive storefront instead of an unfinished elevation.
IMPLEMENTATION PROCESS
Step 1 — Discovery
- Customer shared dimensions and concept goals
Step 2 — Custom Engineering
- Existing Royal Foam profile resized
- Corbels repositioned for exact spacing
Step 3 — Fabrication
- Precision production
- Hardcoat finish
- Paint-ready completion
Step 4 — Delivery
- Shipped ready for installation
Step 5 — Installation
- Fast, simple contractor install
- Accurate fit at mitered corners
RESULTS (KEY METRICS)
- Solved difficult 16-inch façade gap
- Custom-modified profile delivered quickly
- Lightweight install vs masonry alternatives
- Mitered corners aligned perfectly
- Finish visually blended with granite façade
- Excellent value for price and delivery
- Dramatic enhancement of storefront curb appeal
VALUE ANALYSIS (TCO)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
WHY NOT TRADITIONAL MATERIALS?
Traditional Options
- Heavy stone pieces
- Costly custom carving
- Difficult installation overhead
- Longer production schedules
Royal Foam Solution
- Lightweight custom trim
- Easy installation
- Highly detailed appearance
- Faster turnaround and better value