Abstract:
Architectural units having radiused wall corners are constructed with solid surfacing material (SSM) such as Corian. Cove moldings are formed from SSM sheet strips comprising an elongated cove form flanked by elongated rabbet channels. In a table jig, an SSM wall sheet edge is adhesively secured into one of the cove molding rabbet channels. The cove mold and wall sheet unit is secured to the desired architectural wall with the other cove molding rabbet channel mated to an SSM wall sheet edge respective to an adjacent architectural wall. Clamping blocks secured to respective wall sheet and cove mold surfaces by hot melt adhesive are drawn together along the correct vector to adhesively bond each wall sheet edge into a respective rabbet channel.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional of application Ser. No. 09/186,857 filed Nov. 5, 1998, now U.S. Pat. No. 6,155,021, which is a continuation-in-part of application Ser. No. 08/653,406 filed May 24, 1996, now U.S. Pat. No. 5,870,878. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to the fabrication of cabinets and architectural enclosures from solid surfacing material. 
     The term “solid surfacing material” is used by the architectural and habitation construction arts to describe non-foamed, non-laminated polymer-based materials useful for defining and constructing architectural surfaces and elements. These polymer-based solid surfacing materials are typically manufactured substantially of polyester or acrylic resins, alloys and mixtures thereof. Often, natural and/or mineral additives are combined to achieve a desired color or visual pattern in the composite along with fabrication workability and natural feel. 
     Use of solid surfacing materials began as kitchen and bath countertops due to a combination of mechanical and aesthetic properties including moisture imperviousness, durability, workability, ease of repair, ease of cleaning, ease of sterilization and beauty. Since introduction, use of solid surfacing material has spread to countless other applications such as shower enclosure walls and dressing areas. 
     Although a few cast or heat formed specialty shapes such as sinks, lavatories and soap dishes have been made available by primary manufacturers of solid surfacing materials in a few of the most popular colors and styles, for the most part the material is only produced in 30 inch by 12 feet sheets and in ¼ inch, ½ inch and ¾ inch thickness. The widest selection of style and color is available in ½ inch thickness with ¼ inch thickness being the next most available. 
     Plastic solid surfacing materials are available from several U. S. manufacturers such as E. I. dupont de Nemours &amp; Co., Inc. of Wilmington, Del. 19898 U.S.A., who market their polymer based solid surfacing materials under the trademark of “Corian”. “Corian” is a substantially rigid, non-foamed, non-laminated, non-coated solid material composed primarily of acrylic components. “Corian” is most often made and sold in sheet form. U.S. Pat. No. 3,847,865 issued Nov. 12, 1974 to R. B. Duggins and assigned to E. I. dupont de Nemours &amp; Co., teaches one formula for making plastic solid surfacing material of the general nature of that referred to in this description. 
     Another manufacturer of polymer based solid surfacing material is the Nevamar Corporation located at 8339 Telegraph Rd., Odenton, Md. 21113 U.S.A. The Nevamar Corporation markets their solid surfacing material under the trademark of “Fountainhead”. “Fountainhead” is a substantially rigid, non-foamed, non-laminated, non-coated solid material composed of a polymer alloy comprised mostly of polyester components having therein a smaller percentage of acrylic components. “Fountainhead” is most often made and sold in sheet form. 
     Another manufacturer of polymer based solid surfacing material is the Formica Corporation, located at 155-T Rte. 46, W., CN-980, Wayne, J. J. 07470 U.S.A. The Formica Corporation sells their solid surfacing material under the trademark name of “Surell” “Surell,” like “Corian” and “Fountainhead,” is a dense solid plastic most often made and sold in sheet form. “Surell” is a substantially rigid, non-foamed, non-laminated, non-coated solid material composed substantially of polyester components. 
     Du Pont, the Nevamar Corporation, and the Formica Corporation, and several other companies not specifically mentioned, who produce polymer based solid surfacing materials similar to one another, manufacture and sell polymer based solid surfacing materials in sheet form intended for use as walling or countertops, and sometimes make and sell cast or heat-formed shapes made of the same polymer based materials useful as kitchen and bathroom lavatories. 
     Some of the recognized advantages of using polymer based solid surfacing materials such as “Corian”, “Fountainhead” or “Surell” over the available materials such as wood, metal, ceramic tile, and high pressure plastic laminates exists in the fact that the material is a solid, polymeric non-laminated structure in which the color or decorative color patterns extend completely therethrough. If polymer based solid surfacing material does become stained, burned or scratched so deeply that the damage cannot be removed with a common household abrasive cleanser, the damage can be easily removed by light sanding with steel wool or fine sandpaper, and this due to the fact that the material is solid, and the color or visual patterns extend completely therethrough. Furthermore, plastic solid surfacing materials typically have a high tensile strength, are quite hard, dense and rigid, and are resistant to chipping, cracking, splitting, warping, burning, and staining, all of which cannot be said about many other materials which could be used as substitutes therefor. 
     Another attractive quality associated with polymer based solid surfacing materials such as those sold under the trade names of “Corian” “Surell” or “Fountainhead” is the ease of adhesive bonding with available colored glues. Additionally, the polymer based sheets can be easily cut to size or otherwise shaped with mechanical material removal methods and tools using sawing and shaping tools such as router bits, power saws and shapers and the like, similar to those used to cut and shape wood. 
     Polymer based solid surfacing materials such as “Corian” “Surell” or “Fountainhead” may be manufactured at a relatively low price to very closely resemble texture and visually simulate marble, granite, and other natural stone products which have long been desired and used as building materials due to recognition of the durability and beauty of such natural substances. 
     Due to the significant number of available colors and patterns of solid surfacing material in sheet form, there is a growing demand for larger and more complex architectural units having floor to ceiling walls and wall corners. Moreover, owners increasingly request that the corners be coved and rounded to facilitate sanitation and to appear as if carved and polished from a single monolith i.e. completely seamless. 
     Prior art methods for fabricating coved inside corners normally include the bonding of a filler strip along the corner and subsequently routing a radius into the filler strip. This method, however, produces a long, feather edge of the filler strip running into an adhesive layer in the plane of the adjacent wall. This process involves utilizing a specialized jig or tool guide for holding the router at a forty-five degree angle to cut the radius. There is little room for error with this procedure, since routing the cover too deep would cut into the wall, and too shallow a cove would require extensive sanding. The installer, therefore, must be highly skilled in this procedure. In addition, the procedure is time consuming, and is, therefore, relatively expensive. 
     U.S. Pat. No. 5,330,262 to C. R. Peters describes a method of fabricating a coved, countertop backsplash from solid surfacing material wherein the cover fillet seams intersect the respective counter surface planes at substantially 90°. Unfortunately, the Peters method is preferably a shop practiced method that is difficult to carry-out on the field job site of an in situ construction. 
     It is an object of the present invention, therefore, to teach a method of fabricating radiused inside comer walls with solid surfacing material that is suitable for field practice and assembly. 
     Another object of the present invention is to provide special shapes and moldings formed from solid surfacing material sheet stock that facilitate seamless joints. 
     A still further object of the present invention is to provide jigs, clamps and a corresponding assembly method by which a large architectural enclosure such as a bath or shower stall may be fabricated entirely of solid surfacing material without seams or abrupt planar intersections. 
     SUMMARY OF THE INVENTION 
     These and other objects of the invention are accomplished by a solid surfacing material construction method having special moldings for transitional shapes that are partially self aligning. Such moldings are shop milled from stock sheets of solid surfacing material to include rabbet channels along butt joint edges. These rabbet channels are oriented angularly to receive a wall sheeting edge with a radiused cove about the transition. A clamping system is secured to the finish face of the wall sheet and molding by hot-melt adhesive and aligned to draw the back, inside comer of the molding rabbet channel against the back, outside comer of the joined wall sheet. 
     Preparatory to a field assembly, the edge of one wall of an intersecting pair of walls is joined to the respective comer molding piece that is to transition between the two intersecting walls. This joint is secured in a table fixture for a substantially perfect seam line that is 90° to the surface plane. This seam line will subsequently be sanded and polished to obscurity. 
     With the comer molding secured to and finished with one wall of solid surfacing material, the prefabricated wall unit is aligned with and secured to the structural supporting frame. 
     The cooperatively intersecting wall unit is aligned with its respective structural. wall and the other rabbet channel in the molding edge. Surface adhered clamps draw the respective adhesive coated inside comer of the molding rabbet against the outside comer of the wall edge to fill and secure the seam. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention may be further understood by reference to the following description and attached drawings which illustrate the preferred invention embodiments and wherein: 
     FIG. 1 is a partial isometric of a bath tub enclosure. 
     FIG. 2 is a plan view of a bathroom interior construction. 
     FIG. 3 is a sectioned view of a shower wall along a 45° coved corner. 
     FIG. 4 isometrically illustrates a 90° long radius coved comer subassembly jig. 
     FIG. 5 isometrically illustrates a 45° long radius coved comer subassembly jig. 
     FIG. 6 isometrically illustrates a 90° short radius coved comer subassembly jig. 
     FIGS. 7-12 orthographically illustrate in vertical cross-section respective arrangements of the final assembly jig. 
     FIG. 13 s a cross-sectioned fabrication detail of a 90° long radius cove molding. 
     FIG. 14 is a cross-sectioned fabrication detail of a 45° long radius cove molding. 
     FIG. 15 is a cross-section of a right-hand sill molding. 
     FIG. 16 is a cross-section of a left-hand sill molding. 
     FIG. 17 is a cross-section of a door casement molding. 
     FIG. 18 is a cross-section of a door header molding. 
     FIG. 19 is a 90° long radius coved cap molding. 
     FIG. 20 is a 45° long radius coved cap molding. 
     FIG. 21 is a top plan view of a final assembly jig shoe block. 
     FIG. 22 is a cross-section of a final assembly jig shoe block. 
     FIG. 23 is a front elevation of a final assembly jig hinge plate. 
     FIG. 24 is a cross-section of a final assembly jig hinge plate. 
     FIG. 25 illustrates an alternative coved corner jig assembly. 
     FIG. 26 a cross-sectional view of an alternative embodiment for the final assembly jig. 
     FIG. 27 is a cross-sectional view of the bar clamp mounting shoe for the alternate embodiment illustrated by FIG. 26 along the cutting plane  27 — 27 . 
     FIG. 28 is a cross-sectional view of an alternative embodiment for the cove molding element for the invention. 
     FIG. 29 is a cross-sectional view of an alternate embodiment for the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As a representative application of the present invention, FIG. 1 partially illustrates a bathtub alcove having a 90° coved inside wall corner. Dashed lines  10  on the drawing represent the approximate locations of edge joints between adjacent units of solid surfacing material (SSM). In this case, a shop fabricated 90° cove molding  14  is edge jointed to adjacent factory formed planar wall sheets  12 . Factory sheets are normally formed to 30 inch×12 ft. planar perimeter dimensions and ¼ inch, ½ inch and ¾ inch thickness dimensions. Wall sheathing applications, as illustrated by this example, are usually served by a sheet that is ¼ inch thick, 30 inches wide and 98 inches long. 
     FIG. 2 is an architectural plan of a shower enclosure  20  defined by structural stud walls  22 . Inside edges of the studs  22  are sheathed by a moisture resistant wall board  24  which is secured to the stud edges by nails, screws or adhesive. Typically, such wall board is about ½ inch thick. Solid surfacing material (SSM) assembly components comprising wall sheets  12 , 90° cove moldings  14  and 45° cove moldings  16  are adhesively attached to the moisture resistant wall board by structural foam strips  26 , as illustrated by the enlarged detail. of FIG. 3, to provide vertical air circulation and expansion spaces  28  between the inside surfaces of the solid surfacing material and the outside surfaces of the wall board  24 . These polymer sheet strips  26  are usually about¼ inch thick and are secured initially to the SSM backside by silicon adhesive. 
     Joints between adjacent SSM components are secured by color coordinated adhesive. Contiguous edges of adjacent components close to a gap error of preferably no more than {fraction (1/64)} inch. Excess adhesive squeezed from the joint when assembled is, when cured, milled flush to the SSM face and polished with a finishing abrasive. SSM joints fabricated according to this procedure, known to the trade as a “hardseam”, are imperceptible to casual inspection and touch. The entire assembly produces the appearance of being materially integral. 
     The manual effort required to produce such a tactily imperceptible hardseam is greatly reduced by applying a strip of masking tape across the outside surface of the dry outside surface of the assembled joint prior to adhesive application. While assembled dry, the strip of tape bridging the joint is cut with a sharp, thin knife point along the joint. The tape remains on the SSM surface when the joint is assembled with adhesive. As the joined pieces are pulled together and excess adhesive is extruded from the seam, the extruded excess substantially lays over onto the masking tape. After the tape is set but prior to complete cure, the tape is stripped away to carry the excess adhesive bead with it. 
     For the purpose of nomenclature definition, those surfaces of an architectural unit that are constructed to be visually exposed when finished are herein described as “outside” surfaces. The term “architectural unit” is to be interpreted expansively to mean enclosures such as shower stalls, bath tub alcoves, entire rooms, halls, passageways, cabinetry and furniture. 
     Among the several steps essential to the successful construction of such a large, completely hardseamed SSM enclosure as a shower or bath alcove is an accurate milling of the 90° and 45° comer cove moldings  14  and  16 , respectively. Referring to FIG. 12, a cross-section of a 90° cove molding  14  is shown to be formed within the ½ inch thickness t of a standard SSM sheet  11  between opposite surface planes  17  and  19 . Although a wide latitude of design discretion is available, one combination of dimensions includes a 1-¼ inch cove radius r, turned about an 89° arc a and about 1-⅝ inch chord C 1 . The remaining minimum web thickness W 1  at the greatest depth of the cove arc is about ¼ to {fraction (3/16)} inch or the approximate thickness of a ¼ inch wall sheet. At opposite ends of the arc chord C 1  are rabbet channels  30 , each having a longitudinal edge surface  32  and a lap surface  34 . A rabbet channel  30  is formed by the 90° stepped intersection of the planes respective to the edge and lap surfaces. 
     The rabbet channel  30  depth, which corresponds to the edge surface  32  width, is about ¼ inch or substantially the same as the SSM sheet it is to be joined with. The lap surface  34  width is substantially the same as the edge surface. The lap plate  36  is preferably accorded a material thickness of about {fraction (3/32)} inch to allow an approximately {fraction (5/32)} inch expansion space between the wall board  24  and the lap plate  36  backside. See FIG.  3 . 
     Although necessitating additional assembly steps, the FIG. 27 invention embodiment illustrates a molding strip  240  having fabricated rabbet channels  242  that are formed by lap plates  244 . The lap plates may be bonded to either the molding strip  240  or to the respective wall sheets  12   a  or  12   b.    
     FIG. 13 illustrates the construction details of a 45° molding strip that also is milled from a ½ inch SSM sheet thickness. In this case, the arc A 2  is cut to 44°: one degree less than the installation arc of 45°. A chord C 2  of 2 inches will provide a central web thickness W 2  of about ¼ to {fraction (3/16)} inch. The arc A 2  is delineated by rabbet channels  40 . The rabbet lap plate  46  is about {fraction (3/32)} inch thick to allow an approximate {fraction (5/32)} inch expansion space between the wall board  24  and the lap plate  46  back side. See FIG.  3 . 
     Although relatively large architectural units such as shower and bath alcoves require an in situ final assembly, it is strongly preferred that corner cove moldings be jig assembled to one adjacent wall sheet prior to final installation as is shown by FIGS. 4 and 5. The 90° cove molding assembly jig  50  of FIG. 4 is the same jig  50  of FIG. 5 for assembling 45° cove-molding with an accessory strip  59 . Basic construction of the cove molding assembly jig comprises a base plate  52  and a pair of abutment fences  54  and  56 . The first fence is hereafter characterized as a base fencing block  54 . The second fence is hereafter characterized as a cap fencing block  56 . 
     The base plate  52  includes a depressed surface channel  53  of depth below the base plate top surface  60  corresponding to the thickness of the 90° molding  14  lap plate  36  whereby the lap surface  34  is coplanar with the base plate top surface  60  when the extremity of the opposite molding lap plate  37  is in contact with the underside of the cap fencing block  56 . It should be noted that the molding backside reference surface  38  is set at 45° to the base plate  52  top surface plane and the inside surface plane  62  of the base fencing block  54 . 
     The wall panel  12  to be joined with the cove molding  14  is prepared by securing a line of clamping blocks  70  along the wall panel edge at 4 to 6 inch spacings. These blocks  70  are secured rapidly with a minimum volume of hot melt adhesive. Although the clamping blocks  70  are glued to the outside surface of the SSM and therefore will become a finished face of the wall, these blocks are quickly and cleanly removed by a topical application of denatured alcohol followed by a light rap or shock. 
     Each clamping block  70  is about 1-½ in.×1-½ in.×2 in. long with a beveled backface  72 . The bevel angle of backface  72  is set with consideration of the assembly jig  50  dimensions to provide a clampface surface that is substantially parallel with the beveled end face  55  of the jig base plate  52 . 
     So prepared, adhesive is applied to both surfaces  32  and  34  of the molding  14  rabbet channel  30  and the mating edge surfaces of the wall panel  12  and the components positioned in the jig  50  as illustrated. Immediately, while the adhesive remains fluid and workable which is usually 10 to 15 minutes, clamps  80  are applied between the clamping blocks  70  and the base plate end face  55 . Although numerous types and styles of clamps may be used, the cam operated sliding bar type of clamp illustrated has numerous advantages including economy and speed of operation. Such a clamp comprises a bar or beam  82  having an anvil dog  84  and a sliding dog  86 . The anvil dog  84  is rigidly secured to the bar  82  as by pins  85 . 
     The sliding dog  86  includes a slot  87  to slidably receive the bar  82  with sufficient clearance to “wedge” into the bar  82  when sufficient torque is applied to the distal end  87  of the sliding dog  86 . The sliding dog distal end  87  is split by a kerf  88  to provide a rigid base  90  and a mandible  92  that swings about a hinge section  94 . A slot  96  confines a lever engaged cam  98  for rotation about a pin  97 . When the lever  98  is rotated about the pin  97 , the inside cam face not shown bears against the mandible  92  to load the clamp jaw face  93  into the block  70  and press the lower corner of the wall sheet  12  into the inside corner of the 90° molding  14  rabbet channel  30  for the interval required to set the adhesive. 
     When the adhesive has substantially cured, a bead of hardened adhesive that was extruded from the joint line  10  is router trimmed flush with the interior surfaces of the SSM cove  14  and panel  12 . Alternatively, the previously applied masking tape is stripped from the joint flanking forces when the adhesive is set but not completely cured. The remaining ridge of adhesive is sanded away by 300 to 600 grit abrasive paper to a degree of tactile imperceptability. If correctly prepared and positioned, the width of this joint line  10  is less than {fraction (1/64)} inch wide along its entire length and completely filled with adhesive material. Unless the panel  12  and cove  14  core are of visually contrasting color or texture SSM composition, the joint line  10  may be made virtually invisible. 
     Referring to FIG. 5, it is to be noted that the dado channel  58  in the fencing block  54  is filled with the 45° accessory strip  59  to provide a dimensionally controlled abutment surface for the distal edge of one 45° molding lap plate  47 . The other molding lap plate  46  is disposed along the base plate surface channel  53 . The molding backside reference surface  48  is aligned at 22.5° to the base plate  52  top surface plane  60 . In this alignment, adhesive is applied to the rabbet channel  40  and the adjoining edge of SSM wall panel  12  is positioned along joint line  10  and clamped as previously described with respect to the 90° molding jig procedure of FIG.  4 . 
     Referring now to FIG. 6, the same assembly jig  50  is again modified to join a short radius 90° cove molding  15  to a SSM wall panel  12 . The lap plates  66  and  67  remain the same dimensionally as the lap plates  36  and  37  of the long radius cove molding  14 . However, the chord distance between the lap plate ends is considerably less due to a smaller cove radius r 1 . Correspondingly, the backside reference surface  68  is more narrow than backside  38 . In accommodation of these dimensional differences, an auxiliary base fence block  74  and an auxiliary cap fence block  76  are provided to fit within and fill the dimension between the top surface  60  of the jig base plate  52  and the underside of the cap fence block  56 . The overhanging bottom ledge surface  77  of auxiliary cap fence block  76  and the face of auxiliary base fence block  74  serve the lap plate abutment function to confine the short radius molding  15  against the thrust of clamps  80 . 
     Auxiliary base fence block  74  is further modified with a rabbet channel  78  to receive the lap plate of a 45° short radius cove molding not shown but in the same manner as FIG.  5 . 
     An alternative molding attachment jig  140  is illustrated by FIG. 25 as fabricated from a metal channel section  142  having a fence structure or abutment fence  143  with a cap flange  144  and a base flange  146  integrally formed at opposed edges of the abutment fence  143 . The base flange is set in a dadoed channel  154  and secured by screws  148  with the abutment fence  143  standing upright, as shown. The comer of the abutment fence  143  and the cap flange  144  forms an edge abutment pocket  145 . The depth of dado channel  154  below a supporting table top surface  156  corresponds to the molding lap plate  46  thickness. In lieu of a dado channel  154  into the surface of a work table, the same objective may be obtained by attachment of the channel base flange  146  directly to the table surface in combination with a spacer sheet of lap plate thickness under the SSM sheet to be adhesively attached to the molding piece in the jig  140 . 
     To reconfigure the alternative jig  140  to join a 45° molding with a sheet of SSM, it is only necessary to insert dowel pins  152  into the apertures  150  formed in the abutment fence  143  of the channel section  142  to provide a structural abutment line corresponding to an accessary strip. 
     When either or both wall planes of an enclosure are out of “plumb” with respect to a horizontal floor or ceiling plane, the departure from plumb must be measured and accommodated. As an expedient to such measurement, a length of cove molding appropriate for the subject corner, whether 90°, 45° or other, without the lap plates  36  and  37  but with shims to fill the air expansion space  28  between the molding backside and the wall board  24 , the location of the vertical edges  42   a  and  42   b  of the wall panel sheets are marked on the adjacent wall board  24 . This may be done with a short length of modified cove molding used as a gauge at the top and bottom of the wall with the markings linked by a straight line. The resulting line between the top and bottom gauge marks may not be perpendicular to the floor and ceiling, assuming that is desired. In any case, any taper in either of these lines must be transferred to the vertical edges  42   a  and  42   b  of the respective wall panels  12   a  and  12   b.    
     With respect to FIG. 7, a unitized assembly comprising an SSM cove piece  14  and SSM wall panel  12   a  is aligned on the intended wall structure with the mating SSM wall panel  12   b . The unitized SSM assembly, including the polymer foam strips  26   a , is permanently secured by silicon adhesive, for example, to the adjacent wall board  24 . The silicone adhesive allows 10 to 15 minutes of working time before setting. With the unitized assembly of panel  12   a  and cove molding  14  securely in place, the mating edge  42   b  of the SSM wall panel  12   b  is marked with the measured taper and cut to a {fraction (1/64)} in. fit with the molding rabbet channel  30   b . Next, a shoe block  100  is secured to the outside surface of the unitized assembly by a hot melt adhesive in the same manner as clamping blocks  70  were secured. A cooperative base block assembly  110  is similarly secured along the edge  42   b  and outside face of the unattached wall panel  12   b . The foam strips  26   b  are adhesively applied to the backside of the panel. 
     A silicone adhesive is applied to the inside surfaces of the foam strips  26   b  and the panel  12   b  is positioned on the wall with the edge  42   b  aligned to the rabbet channel  30   b  of the cove molding  14 . The alignment is initially made “dry”, meaning that no SSM adhesive is on either of the joint surfaces. When the alignment of edge  42   b  in channel  30   b  is of acceptable quality, the silicone adhesive is allowed to complete the setting interval. 
     With both wall panels  12   a  and  12   b  securely positioned, the cove molding edge of the unitized assembly may be manually deflected against the wall board  24  to expose the edge  42   b  of the panel  12   b . So exposed, SSM adhesive is applied to the appropriate surface portions and the joint permitted to close. The multiplicity of eye bolts  102  anchored by a pin  104  to the shoe block  100  are positioned to bear against a folding anchor plate  112  and by resulting tensile force, secure the two SSM wall elements along the adhesive coated rabbet channel  30  compression juncture. 
     Referring to FIGS. 21 and 22, a shoe block  100  is seen to comprise an elongated rectangular base of a suitable material such as a solid hardwood or strip of SSM scrap. Although a shoe block  100  may be as long as a molding element, such continuity is not essential. In most applications, several shoe blocks, each of 2 to 3 feet length, are more conveniently handled and positioned. One elongated comer of the block is shaped to a convenient curvature  101 . For example, a curvature of equal or less radius than the short radius cove of molding  15 . 
     At uniformly spaced increments along the length of the shoe block, slots  103  traversing the block depth from a top face  106  to the base of curvature  101  are cut at uniform increments of, for example, 3 to 6 inches. Fingers  105  of block structure between the slots  103  accommodate a longitudinal bore in receipt of the eye bolt  102  retaining pin  104 . 
     With respect to FIGS. 23 and 24, the base block assembly  110  is seen to comprise the folding anchor plate  112  and the base plate  114  connected by a hinge  116 . Similar to shoe block  100 , slots  118  delineate structural fingers  117  of about the same width as fingers  105  on the shoe block. 
     The same jig combination of shoe block  100  and base block  110  is used in several assembly configurations as are represented by FIGS. 8-12. FIG. 8 illustrates the same long radius 90° cove molding assembly as is shown in greater detail by FIG.  7 . FIG. 9 illustrates the jig alignment for a long radius 45° cove molding  16 . FIG. 10 assembles a short radius 90° cove molding  15  by reversing the shoe block  100  and attaching the shoe block backside  106 . Similarly, the reverse turned shoe block  100  backside  106  is also used to assemble the short radius 45° molding  18  as illustrated by FIG.  11 . Additionally, FIG. 12 illustrates the reversed shoe block  100  used to secure a butt joint  107  between two wall panels  12   b  and  12   c  in the same plane. In this case, a set of lap fingers  108  and  109  are used to lap the butt joint  107 . 
     As will be noted from FIGS. 8 and 10, some of these assemblies bring the outer surface of shoe block  100  into close proximity with the erected anchor plate  112  of the base block  110 . For manual access to the seam line and visual confirmation of the joint quality, it is convenient to fold the anchor plate  112  down against the base plate  114  during the initial joining steps. When the craftsman is satisfied with the joint quality, the anchor plate  112  is raised and the eye bolts  102  laid into the slots  118 . The wing nuts  113  are turned on the eye bolt  102  threads into bearing against the fingers  117 . In consequence, the joint assembled is subjected to moderately high, uniformly distributed compressive load during the adhesive curing interval for an invisible, razor thin joint line. 
     FIGS. 26 and 27 illustrate another assembly jig combination having a multiplicity of individual shoe blocks  200  distributed along a joint edge. Each of the shoe blocks  200  has a full length slot  204  for accommodation of a clamp bar  202 . One end of the clamp bar  202  is secured to the shoe block  200  by a pivot pin  206 . The reach end of the clamp bar  202  accommodates a sliding clamp dog  210  having a mandible  212  engaged by a cam  214 . A base block  220  is secured to the outside surface of the SSM wall panel  12   b  by hot melt adhesive as previously described. An anchor plate  222  hinged to the base plate  224  is rotated to a position of convenient engagement by the clamp dog mandible  212 . 
     FIG. 28 illustrates the shoe block  200  jig assembly engaged with a base block  230  to secure a buttjoint  107  between two wall panels  12   b  and  12   c  in the same plane. A pair of lap fingers  108  and  109  lap the butt joint  107 . 
     The preferred embodiments of my invention have been described relative to 90° and 45° cove moldings. However, numerous other trim and finish treatments may be fabricated with the same process. FIGS. 15 and 16 respectively illustrate opposite hand turns  120  and  122  of sill molding that joins with a SSM sheet edge along the rabbet channels  124  and  126 . FIG. 17 illustrates a typical door casement molding  130  having rabbet channels  132  and  134  respective to opposite wall faces. FIG. 18 illustrates a door header  140  that receives a chamfered SSM sheet edge in the round bottom groove  142  along an offset from the surface edge to produce a lip  144 . 
     FIGS. 19 and 20 illustrate cap moldings respective to 90° and 45° cove molded walls for a finished terminal on a knee-wall or other exposed wall top edge. 
     While the preferred embodiments of my invention are described above, it will be appreciated by those of ordinary skill in the art that the invention is capable of numerous modifications, rearrangements and substitutions of parts without departing from the spirit and scope of the appended claims. 
     As my invention, therefore,