Jeff Doubet shares a Before + After Spanish ceiling project and how raised details were created using foam fretwork and common materials used in Spanish-style home construction. Go inside this Montecito, CA interior remodel to see how these talented Artisans figured everything out. Scroll to learn of off-the-shelf products manufacturers now make to achieve the look in a lot easier way today.
BEFORE PHOTO: The new homeowners had just purchased a fixer upper in a high-end neighborhood of Santa Barbara. The problem was that the interior was in a major need of a refresh. The existing coffered ceiling had a dark, faux finished paint treatment. And, the mismatched wallpaper and heavy window trim had to go.
AFTER PHOTO: These Spanish style ceiling panels were hand-made with fretwork in the San Felipe pattern. Throughout the house, we were using the popular design infused into other elements such as tile and plaster grilles. We thought it would be cool to do a ceiling, too.
FYI: I wanted you to see this AFTER PHOTO early in my post, so you could have context for the myriad of process photos that follow.
Making Large Spanish Ceiling Panels with Architectural Foam
Back in 2013, we really didn’t know how we were going to accomplish the goal of making oversized ceiling panels with a Spanish motif. But, I have a friend who owns a custom fabrication shop that specializes in architectural foam.
I gave him a call, describing what we were trying to do. For decades he has made other custom components for my designs and client projects. He quickly said “Draw it up! I’ll program the computer, and make it happen- no problem”.
I carefully measured the sections of the existing ceiling, and sketched a scaled drawing for the size and layout for the Spanish “San Felipe” pattern. Since our coffered ceiling was already there, I sized the custom panels to fit exactly into those predetermined spaces.
See other Spanish-style ceiling resources.
Applying A Decorative Surface to Architectural Foam
Many people do not know that architectural foam is regularly used in high-end Spanish style homes and commercial building projects throughout Santa Barbara and Montecito, CA. There are different materials to coat and finish the foam, and this depends on the location where the foam will be installed.
For this residential Spanish interior project, we are applying a mix of All Purpose Drywall Mud with 20 min. compound for a quick cure, subtle Old World finish on our foam ceiling panels and the skylight grille. These photos show the texture I am achieving by hand.
*As an Amazon Associate, I earn commissions from qualifying purchases, at no extra cost to you. Thank you for your support!
For the whole house remodel, I also designed this “Stars and Crosses” grille. As soon as we finished the grille, it was installed in a laundry room skylight well.
I regret not having captured a few photos of the raw architectural foam components as they were delivered to the site. At the time, we were receiving a wide variety of other foam components for the project. I just wanted to begin finish work on these extra special pieces.
With our local fabricator, the architectural foam can be ordered in varying degrees of density. The higher the density, the more resistant to dents and damage. Keep in mind creating a higher density part does requires more material (which adds to the cost of the component). In our case, the parts were going to be installed far out of reach, so we saved money by specifying a lower density foam.
How We Made Large Spanish Ceiling Panels with Architectural Foam Fretwork
Continuing to consult with our local architectural foam fabricator, he advised that he would first build our custom Spanish ceiling panels in sectioned layers. One layer would be the decorative fretwork. The other, a solid sheet of foam for the back panel.
The decorative “San Felipe” Spanish-style pattern fretwork was cut out of 1″ thick foam using a Hot Wire Foam Cutting CNC Machine.
The lace-like, custom cut 1″ thick foam San Felipe fretwork was then glued to the 1″ thick back panel. In these photos the Artisan builders are applying the quick cure drywall mud compound mix. For this project, we discovered it was easiest to apply it with our fingers.
Once the compound is set up a bit (but not fully hardened), it is “smoothed out” with a moist sponge. This saves time in fabrication, and eliminates the need for an optional (dusty) sanding process.
ABOVE: A talented Artisan builder uses a moist Grout + Washing Sponge to smooth out the compound. It is also a way to create the subtle radius we wanted to achieve between the fretwork and the background panel.
*As an Amazon Associate, I earn commissions from qualifying purchases, at no extra cost to you.
ABOVE: A close up of our fast curing drywall compound slurry. It worked great to fill the seams where the fretwork meets the back panel.
I will admit the process of creating these Spanish ceiling panels was tedious. It required a lot of concentration, balance and hand/eye coordination to get things just right.
How-To Tips For Sanding and Finishing Decorative Spanish Wall + Ceiling Tiles
We got just the right look to our Spanish ceiling panels by the combination of using damp sponges and flexible sanding blocks.
We used Sanding Block Sponges sparingly, as they create dust. But they are a great tool for flattening areas on the drywall mud finish. Something the moist sponge technique cannot achieve. The sanding wedges are flexible and can be shaped to your piece.
As an Artisan team, we went back and forth applying wet mud to certain sections of the San Felipe ceiling panels while simultaneously dry sanding other sections.
I shot these photos in February of 2013 while showcasing the process we had for making these large Spanish style ceiling panels. Back then, there were no “off-the-shelf” products available to purchase. We were inventing our way, as we created something cool.
Techniques for Installing Large Spanish Ceiling Panels
We completed the majority of the construction of our Spanish-style ceiling panels while they were on the ground. It was easier in many ways, including on our neck and shoulders. But now it was time to install them on the ceiling.
We used a high quality construction adhesive that does not melt Styrofoam. This is very important when gluing architectural foam to itself, and other materials. If you use adhesives that contain acetone, you will ruin your beautiful part in seconds.
*As an Amazon Associate, I earn commissions from qualifying purchases, at no extra cost to you.
In the photos above, you will see mounting screws and washers we have started to install on the ceiling panels.
In the photo above you can see how we mounted the 1″ diameter washers and 3.5″ long drywall screws. We picked intersections of the raised fretwork as the best locations for this additional support for the ceiling panels while the adhesive cured.
Once the ceiling panels were glued and secured to the ceiling, the Artisans began caulking the outer edges.
The long drywall screws with 1″ dia. washers were installed to dig slightly into the foam panels. This enabled us to come back and patch over them, so as to complete a seamless installation.
Where to Buy Spanish Ceiling Panels
Over a decade has passed since we accomplished this custom Spanish ceiling. Now, there are new companies popping up and making products that can make the process easier.
Ekena fabricates a kit with a nearly identical shape that closely replicates what we have done in our early 2013 project.
*As an Amazon Associate, I earn commissions from qualifying purchases, at no extra cost to you.
A similar three dimensional look of our 1″ thick Spanish style fretwork (above), can now be purchased on Amazon.
Visit Amazon to learn more about manufacturers that sell off-the-shelf kits to achieve a similar result of what we have done in this post.
*As an Amazon Associate, I earn commissions from qualifying purchases, at no extra cost to you.
Whether you are a DIY person or a professional designer, artisan or general contractor- there are now a variety of companies that can help you make a similar look for your own project.
Well friend, this wraps another site visit episode in beautiful Santa Barbara, California. I hope you enjoyed learning how to infuse more Santa Barbara Style into your own Spanish interior design project. Scroll to explore more helpful links and resources for designing and building your own Spanish-style home and landscape.
