Case studies give homeowners something that cost guides and process articles cannot, a real look at how a custom home build actually unfolds from start to finish. This post walks through a completed custom home project by D.E. Mitchell Construction in the New Bern NC area. It covers the starting conditions, the decisions made along the way, the challenges that came up, and what the finished project delivered for the homeowner.
Project Overview
Location: Rural Craven County, NC Lot Size: 1.8 acres Home Size: 2,340 square feet conditioned space, plus attached two-car garage Bedrooms: 3 Bathrooms: 2 full, 1 half Foundation Type: Crawlspace Primary Exterior: Fiber cement siding, architectural shingles Interior Finish Level: Mid to upper mid-range Timeline: 11.5 months from contract signing to certificate of occupancy Total Construction Cost: $498,000 (excluding land)
The Homeowners & Their Starting Point
A family of four, two adults and two school-age children, had been renting in New Bern for three years while looking for a home to buy. The existing inventory in their price range and preferred area consistently came up short. The homes that were priced right had layouts that did not work for their household. The homes with the right layout were either in areas they did not want or required renovation investment that pushed total cost well above their budget.
After eighteen months of searching, they shifted their approach. They purchased a 1.8-acre lot in rural Craven County, approximately 12 miles from downtown New Bern, and began the process of building a custom home on it.
Their priorities were clear going into the project:
- A primary suite on the main floor with a private bathroom and walk-in closet
- A dedicated home office separated from the main living area
- An open kitchen and living space suited for a family that cooks together and entertains regularly
- A mudroom entry from the garage for a household with kids and a dog
- A covered back porch for outdoor use across most of the year
- Durable materials that would hold up with two kids and a dog without requiring constant maintenance
- A construction budget of $480,000 to $520,000 for the home itself, not including land
These priorities shaped every decision from floor plan development through finish selection.
Phase 1, Pre-Construction
Lot Assessment
The lot had been purchased before D.E. Mitchell was brought into the project. The first step was a thorough site assessment to understand what the lot conditions would mean for the build.
The assessment revealed the following:
Flood zone status: The lot was partially in a Zone X (minimal flood hazard) and partially in a Zone AE (Special Flood Hazard Area). The building footprint was located within the Zone X portion of the lot, which avoided the elevation requirements that would have applied in Zone AE. This was confirmed by a licensed surveyor before design work began.
Soil conditions: Soil borings revealed moderately expansive clay soils in the upper layers, transitioning to more stable material at depth. This affected the footing depth specification, footings were designed to extend below the problematic upper layer.
Clearing scope: The lot had mixed vegetation, open grass in the front half and a wooded rear portion. The building footprint and driveway corridor required clearing of approximately half an acre of mixed pine and hardwood. Clearing scope was estimated at $8,500.
Utility connections: The lot was not served by municipal water or sewer. A well and septic system were required. Perc testing confirmed the soil was suitable for a conventional septic system. Well and septic installation was budgeted at $22,000 and was permitted separately from the building permit.
Driveway: A 280-foot gravel driveway from the road to the home site was required. Budgeted at $6,500 including culvert installation at the road crossing.
These site conditions were incorporated into the project budget before design work began. The total site preparation budget came in at $42,000 including clearing, grading, driveway, well, and septic.
Design & Floor Plan Development
The homeowners worked with a local draftsperson to develop the floor plan. D.E. Mitchell was involved in the design review from the start, reviewing the drawings for constructability, flagging details that would create problems during construction, and providing cost feedback as the plan developed.
Two significant plan revisions occurred during the design phase:
Revision 1, Garage placement. The original plan placed the attached garage on the left side of the home, which created a long hallway between the garage entry and the kitchen. The family’s daily entry pattern, coming in from the garage with groceries, kids, and gear, made a direct connection between the garage entry and the kitchen and mudroom the better solution. The garage was shifted to the right side of the home and the mudroom and kitchen were repositioned accordingly. This change added two weeks to the design phase but eliminated a layout problem the family would have dealt with daily.
Revision 2, Back porch size. The original plan included a 10×14 covered back porch. During a review meeting, the homeowners recognized that a porch this size would not accommodate the outdoor dining and seating they had in mind. The porch was expanded to 12×22 with a vaulted ceiling. The structural change to accommodate the larger porch required a revision to the roof framing plan. The cost addition was $4,200.
Final construction drawings were completed and submitted for permit review eleven weeks after the initial design engagement.
Material Selections
Selections were completed concurrently with the design phase. The homeowners used a selections schedule provided by D.E. Mitchell with deadlines for each category tied to the construction timeline.
Key selections made during pre-construction:
- Exterior siding: HardiePlank fiber cement in Cobblestone finish
- Roofing: Architectural shingles, charcoal
- Windows: Vinyl double-hung, low-E glass
- Kitchen cabinets: Custom maple, painted white, shaker doors, built in-house by D.E. Mitchell’s woodwork team
- Kitchen countertops: Quartz, Calacatta Gold
- Kitchen flooring: Large-format porcelain tile, 24×24
- Primary bathroom tile: Porcelain tile in 12×24 format, wall and floor
- Primary vanity: Custom double vanity, painted finish, quartz top, built in-house
- Secondary bathrooms: Stock vanities, ceramic tile
- Main living area flooring: Engineered hardwood, wire-brushed oak
- Bedrooms: Carpet
- Interior paint: Benjamin Moore Chantilly Lace throughout
- HVAC: 16-SEER heat pump system, two zones
- Water heater: Heat pump water heater
All selections were documented in the specification sheet and incorporated into the contract before signing.
Permitting
The permit application was submitted to Craven County Building Inspections. The application included construction drawings, a site plan showing setback compliance, energy compliance documentation, and structural calculations for the engineered lumber floor system and the porch roof framing.
Plan review took 19 business days. One comment was issued regarding the porch roof connection detail, the drawings were revised, resubmitted, and approved within four business days. The permit was issued 24 days after the original submission.
Long-lead items were ordered at permit submission:
- Windows ordered at week 1 of permitting, 6-week lead time
- Custom cabinets ordered at week 2 of permitting, 7-week lead time
- Heat pump water heater ordered at week 3, 3-week lead time
Windows and cabinets arrived during the framing phase, ready for installation when needed. No material delays affected the construction schedule.
Phase 2, Site Preparation
Site work began the week after the permit was issued.
Week 1: Tree clearing of the building footprint and driveway corridor. Approximately 0.5 acres cleared. All usable timber was cut and stacked for the homeowner’s use. Brush and stumps were removed.
Week 2: Rough grading of the building pad and driveway corridor. The building pad was cut to the appropriate elevation with positive drainage away from the home site in all directions.
Week 3: Gravel driveway installed with culvert at the road crossing. Well drilled and cased, water found at 62 feet. Pump and pressure tank installed and tested.
Week 4: Septic system installed, conventional gravity system with 1,000-gallon tank and drain field positioned in the rear portion of the lot. System inspected and approved by the Craven County Environmental Health Department.
Week 4: Erosion control installed. Temporary power set up at the building site.
Site preparation was completed in four weeks, on schedule.
Phase 3, Foundation
The crawlspace foundation began immediately after site preparation was complete.
Footings were excavated to 30 inches below grade, deeper than the standard 12-inch minimum required by code, to extend below the problematic upper clay layer identified in the soil borings. This decision added approximately $2,800 to the foundation cost and was the right call based on the soil conditions.
Perimeter foundation walls were formed and poured using 8-inch concrete block. Anchor bolts were set at code-required spacing. The crawlspace interior was graded and compacted. A 6-mil poly vapor barrier was installed across the full crawlspace floor. Crawlspace vents were installed at the required spacing.
The foundation inspection was completed and passed on the first visit.
Foundation phase duration: 17 days.
Phase 4, Framing & Roofing
Framing began the day after the foundation inspection passed.
Floor system: Engineered I-joist floor system with 3/4-inch tongue-and-groove plywood subfloor, glued and screwed. The engineered joist system was specified for its dimensional stability, standard dimensional lumber floor systems in Eastern NC’s humidity frequently develop squeaks as the lumber dries and shrinks after construction.
Wall framing: 2×6 exterior wall framing throughout. 2×6 framing versus the code-minimum 2×4 allows for a full 5.5 inches of insulation in the wall cavity, meaningfully improving the wall’s thermal performance.
Roof framing: Engineered trusses for the main roof, site-framed rafters for the covered back porch with its vaulted ceiling. The porch roof was framed with a ridge beam and exposed rafter tails at the eave line.
Windows & doors: Windows arrived during week 3 of framing and were installed immediately. Exterior doors installed concurrently.
Roof sheathing & roofing: Roof sheathing installed. Ice and water shield applied at all eaves, valleys, and penetrations. Synthetic underlayment over the field of the roof. Architectural shingles installed by roofing subcontractor. Flashing installed at all penetrations and transitions.
Framing inspection passed on the first visit with no corrections noted.
Framing and roofing phase duration: 7 weeks.
Phase 5, Mechanical Rough-In & Insulation
All three mechanical trades worked in sequence with each rough-in inspected before the next trade proceeded.
Plumbing rough-in: Supply and drain lines run to all fixture locations, kitchen, two full bathrooms, half bath, laundry room, and exterior hose bibs. Vent stacks installed. Two-week duration. Inspection passed first visit.
Electrical rough-in: All circuits run from the 200-amp main panel. Arc-fault protection on all bedroom circuits. Ground-fault protection in all wet areas. Dedicated circuits for kitchen appliances, HVAC equipment, heat pump water heater, and EV charging outlet in garage. Two-week duration. Inspection passed first visit.
HVAC rough-in: Two-zone duct system installed, main floor zone and bedrooms zone, each with its own thermostat. Equipment platforms built in the crawlspace for the air handler units. Two-week duration. Mechanical inspection passed first visit.
Insulation: 2×6 wall cavities filled with R-21 fiberglass batts. Rim joists spray-foamed with closed-cell foam. Attic insulated with blown fiberglass to R-38. Insulation inspection passed first visit.
Mechanical rough-in and insulation phase duration: 8 weeks including inspection scheduling.
Phase 6, Interior Finishes
The interior finish phase ran 10 weeks.
Drywall: 5/8-inch drywall on the main ceiling for improved sound performance. Moisture-resistant drywall in all bathrooms and laundry room. Three-coat finish throughout. Duration: 3 weeks.
Interior trim: Base molding, door and window casing, and interior doors installed. Crown molding in the primary bedroom and living area. Duration: 10 days.
Cabinet installation: Custom kitchen cabinets and primary bathroom vanity delivered from the D.E. Mitchell shop and installed by the same team that built them. Secondary bathroom vanities installed. Duration: 5 days.
Countertop templating & installation: Kitchen countertops templated after cabinet installation was confirmed level. Quartz fabricated and installed 9 business days after templating. Primary bathroom quartz top installed at the same time. Duration: 2 weeks including fabrication.
Flooring: Large-format porcelain tile installed in kitchen and dining area. Engineered hardwood installed in living room, hallways, and primary bedroom. Carpet installed in secondary bedrooms. Duration: 10 days.
Painting: Primary coat applied after drywall and trim. Touch-up coat after flooring. Duration: 8 days total across two visits.
Plumbing trim-out: Faucets, sinks, toilets, showers, and tub installed and connected. Duration: 4 days.
Electrical trim-out: All outlets, switches, and lighting fixtures installed and connected. Panel finalized. Duration: 4 days.
HVAC trim-out: Grilles, registers, and thermostats installed. Systems commissioned and tested. Duration: 2 days.
Appliances: Range, dishwasher, refrigerator, and microwave delivered and installed. Duration: 1 day.
Phase 7, Final Inspections & Close-Out
Final building, electrical, plumbing, and mechanical inspections were scheduled and conducted over a five-day period.
Building inspection: Passed first visit. Electrical inspection: Passed first visit. Plumbing inspection: One correction noted, a cleanout access cover in the crawlspace was not at the required height. Corrected same day. Re-inspection passed the following day. Mechanical inspection: Passed first visit.
Certificate of occupancy was issued four days after all inspections passed.
Final walkthrough: The homeowners and project lead walked the completed home over approximately two hours. The punch list included:
- One cabinet door hinge adjustment in the kitchen
- A touch-up paint item in the primary bedroom closet
- A grout line in the kitchen tile that needed filling
- One HVAC register that was not fully seated
All four items were resolved within two days of the walkthrough.
Challenges Encountered & How They Were Handled
Challenge 1, Footing depth increase. The soil conditions identified in the pre-construction site assessment required footings deeper than the code minimum. This was identified before construction started, incorporated into the foundation plan, and priced in the contract. It was not a surprise, it was a known condition managed through proper pre-construction assessment.
Challenge 2, Porch roof revision during design. The structural revision required to accommodate the larger covered porch affected the roof framing plan and required a drawing revision before permit submission. The revision was handled during the design phase, not during construction, which meant it added two weeks to the design timeline rather than causing a delay and cost increase during framing.
Challenge 3, Plumbing inspection correction. The cleanout access issue noted during the plumbing final inspection was a minor installation error. It was corrected the same day the inspection occurred. The re-inspection was scheduled the following morning and passed. The total impact on the project timeline was one day.
No material delays. Long-lead items ordered at permit submission arrived on schedule. This is a planning outcome, not luck, ordering materials at permit submission rather than waiting for permit approval is how schedule risk from material lead times is managed.
What the Homeowners Got
At certificate of occupancy, the family moved into a 2,340 square foot home that met every priority they identified at the start of the project:
- Primary suite on the main floor with a private bathroom and walk-in closet
- Home office separated from the main living area by a hallway
- Open kitchen and living space with custom cabinetry, quartz countertops, and a layout that works for how they cook and entertain
- Mudroom directly off the garage entry with built-in storage
- Covered back porch at 12×22 with a vaulted ceiling, ceiling fan, and outdoor lighting
- Engineered hardwood throughout the main living areas, tile in the kitchen, carpet in the secondary bedrooms
- Two-zone HVAC with a heat pump water heater for energy efficiency
- Fiber cement siding and architectural shingles specified for Eastern NC’s climate
Total construction cost came in at $498,000, within the $480,000 to $520,000 budget established at the start of the project. The two budget additions, the footing depth increase and the porch expansion, totaled $7,000 combined and were absorbed within the contingency reserve. The contingency reserve was not fully consumed.
Timeline from contract signing to certificate of occupancy: 11.5 months.
What This Case Study Shows About Custom Home Building in Eastern NC
A few things this project illustrates that apply broadly to custom home building in New Bern and the surrounding area:
Pre-construction investment pays off during construction. The soil assessment, flood zone confirmation, and utility planning done before design work began meant that site preparation proceeded without surprises. The footing depth issue was known and priced before the contract was signed, not discovered after the foundation crew was on site.
Long-lead material ordering is a schedule management tool. Windows and cabinets ordered at permit submission arrived during the framing phase. No phase of construction waited on a material delivery.
Design revisions belong in the design phase. Both significant changes to the floor plan, the garage placement and the porch size, happened during design review, not during construction. Changes made during construction cost more and take longer. Changes made during design cost nothing beyond drafting time.
A detailed specification sheet at contract signing protects the budget. Every material in this home was documented in the specification sheet before the contract was signed. There were no mid-project selection changes and no disagreements about what was included in the contract price.
Frequently Asked Questions
How typical is an 11.5-month timeline for a custom home in Eastern NC?
For a mid-range custom home in the 2,000 to 2,500 square foot range on a rural lot with a well and septic system, 10 to 13 months is a realistic range. Projects on lots with municipal utilities and minimal site preparation can come in faster. Projects with more complex designs, flood zone foundation requirements, or larger square footage take longer.
How close did the project come in to the original budget?
The final construction cost of $498,000 was within the $480,000 to $520,000 budget established at project start. Two scope additions totaling $7,000 were absorbed within the contingency reserve. The project did not require any budget increase beyond what was established at contract signing.
What was the biggest factor in keeping the project on schedule?
Long-lead material ordering at permit submission and completion of all material selections before construction started. Neither windows nor cabinets caused a schedule delay because both were ordered early enough to arrive when needed. No selection was still open when the phase requiring it began.
Can D.E. Mitchell build a similar home for me in the New Bern area?
Yes. We are taking on new custom home projects in New Bern, Havelock, Morehead City, Jacksonville, and the surrounding Eastern NC communities. Reach out to schedule a consultation and we will discuss your lot, your priorities, and what a project like this would cost and take in your specific situation.
Build Your Custom Home in Eastern NC With D.E. Mitchell Construction
D.E. Mitchell Construction builds custom homes across Eastern NC. If you are planning a custom home project and want to talk through what the process looks like for your specific lot and goals, reach out and we will set up a conversation.
No obligation. No pressure. A direct conversation about your project and what it will take to build it right.