Howdy Folks,
I want to cover my porch with a nicely built beam structure, mostly I’ll be using 4X6 and 4X8 beams. My question is this: I want to cut some nice decorative ends on the beams, I’ve seen some elongated ogee profiles I like, but what tools are needed to do this?
Can’t use the bandsaw cause the beams are too darn heavy and long, I think my sawzall would probably butcher the ends, long jigsaw blade might work, if there is suck a creature, but it would probably wander out of square. The circular saw could be used to start the cuts, but the curves have me stumped.
I was thinking maybe one of those portable milwaukee bandsaws, the handheld kind, but I don’t see any guide or table to keep the unit square to the beam.
Any tips are much appreciated.
Thanks,
Brian
Replies
Try posting on Break time they will have the best advice.
Hasta luego,
Mike
Hey Brian, If I were you I would try to think of a way to build them up, so that the middle part was pre-cut on your band-saw, then maybe you could box in the OS, and then use a router to finish up the outside. Here is why I think you will want to think that way.
http://www.timberwolftools.com/tools/kind/bandsaws.html
Brian, like the other Mike said, try posting this at Breaktime.
What I usually do for this kind of cut is to make a pattern out of 1/2" plywood. Use a jigsaw to get close to the line, then use a long straight bit on a big router to get the profile. I have a 2" long top-bearing bit I use for the first cut, which works for stock up to 1 1/2" thick. For stock up to 2", remove the pattern and follow the cut you just made for the extra 1/2" of depth.
For stock between 2 and 4 inches, flip the workpiece over and use a 2" bottom-bearing bit to finish the cut. If you're working on stock over 4" thick, well, I'm out of tricks.
Mike
Have you considered a Bow Saw?
On one of the This Old House episodes Tommy mounted the band saw on wheels and moved the bansaw to cut the ends of some large beams. This might work for your project.
Tim
Hey there all,
Thanks for all the great advice, I like the all the ideas, especially the one about the bandsaw mounted on wheels, I could see this working well and quite easy to do. I could just take the legs off my 14" saw and make a base that would put the table right around saw horse height, and voila, nicely detailed beams. This methos would of course require some good quality wheels, and a smooth floor to work on.
I,ve haven't had a lot of luck posting over at breaktime, I think all you guys are a little more creative, or maybe that's crazy?
If anyone else has any nifty ideas I would appreciate all the info I can get.
Thanks,
Brian
For the smooth floor part, just throw down a sheet of plywood. If the floor is concrete, thin hardboard would work quite well.
The bandsaw on wheels sounds scary to me. I can too easily envision the blade binding or getting twisted or pulled off the wheel. That would suck.
Mike
brianmexico,
Would it be unacceptable to cut the end off, shape it the way you like and put a big old floating tenon between the two pieces...kinda like the way a staircase banister is built..
Mudman,
Good point about the binding, you'd have to manuever this just right and have lots of relief cuts to keep out of trouble. Being very careful, and choosing the right blade, it could work well with some practice.
To others,
I understand the idea about sistering a piece to the end of the beam but because much of this structure will be visible I would like to avoid this if possible. It could look a little contrived if it weren't done just right.
Thanks for all the great tips,
Brian
Brian,
I have cut a few beams with decorative tails .As mentioned the band saw on wheels works well but you have to be real carefull of the blade binding , breaking ,or comeing of the wheels, but I have done them this way. depending on how long the beams are you can have a freind or two help you make the cut by holding the beam.Or you can get a smaller bandsaw and build a jig that would rotate closer to your work. There a is bandsaw designed for this purpose kind of expensive ,but if your doing enough it might be worth while, sorry I dont know the name off the top of my head , I think I've seen them advertised in the back of the magazines.
If you have access to a bandsaw (a stationary one!), the easy way to do it is to cut the end off the beam, bandsaw the pattern, and then fasten the end back on to the beam. Put the seam back up under the roof overhang so it is protected from the weather. You can get elaborate about the joinery, but simply sistering on lumber on both sides of the beam works. After all, the joint isn't holding up the roof -- just the end of the beam.
How thick will the beams be? 4"?
why don't you just use a router from each side with a 1/4" plywood template? You can use a template guide and straight bit to start defining the cut from each side. Rough off the waste with your sawzall, and clean it up with a top-bearing bit from each side- Freud makes ones with up to 2" long cutters that you should be able to use. clean it up with a belt/pad sander (or a spokeshave..)
Bit costs about 70 bucks, but cheaper than the alternatives. A couple of extra steps involved but I think its doable.
The older I get, the better I was....
Papa,
The thickness is about 3.5 inches so it would work fine. Í already have one of these bits, so I'll give your method a shot. It's probably easier than the bandsaw.
Thanks,
Brian
good answer papanick, I saw an episode on the new yankee workshop where norm did the same thing with a long straight cutting bit, and thankx for telling me where i cdan get a long straight cutting router bit
Just me so...
A chain saw and angle grinder for the rough out.. Finish cut with whatever...
Will,
Is that before or after the tequila??
Take Care,
Brian
(P.S. to novice woodworkers, don't drink and work with your powertools, unless it's beer and it's reaaally hot outside)
Brian.. Sorry.. I was serious...Not exactly what you are planning to do but I helped a friend with a horse stable and we had to cut/trim some large timbers.. Many had to match existing fancy tops and stuff like that...We used a mid sized electric chain-saw and a angle grinder.. Finish the cuts with chisels and planes.. Worked out quite well...Angle grinder SURE cuts wood fast and scares the horses!HAY! They make ice carvings with chain saws!
Will,
Don't appologize, I was just havin fun.
I've seen attachments for grinders that look like little mini chainsaw discs used for carving I believe. Is this what you used??
Cheers,
Brian
NO.. To expensive for me! Just a plain old really noisy angle grinder that is used for metal work.. Same disks also.. Cut wood a bit 'rough' but we had to finish it off anyway..If you have a angle grinder grab a big old hunk of wood scrap and grind away.. May surprise you! It actually works out very well...As I recall we made some cardboard templates of the existing 'fancy' stuff.. Got a old can of spray paint and made out 'outline'...Hacked away as close as possible to the pattern and finished with our 'Good' tools...EDIT! I forgot! Get one of those 'flip down' face sheilds! YOU WILL NEED IT!
Edited 8/19/2005 11:37 am ET by WillGeorge
Thanks Will,
I'll give your technique a shot, an I'll save the tequila for AFTER I'm done 8-)
Cheers,
Brian
Brian,
My wife and I would love to do the same thing that you are doing. Do you have any pictures/plans that you could post?
Regards,
Buzzsaw
"Don't ask yourself what the world needs. Ask yourself what makes you come alive, and go do that, because what the world needs is people who have come alive." Gil Bailie
Buzz,
Right now I just have a few pictures out of the home and architectural magazines that you can buy pretty much anywhere. I'm just going to build the whole thing as I go. I like to build things this way because I don't limit myself to a certain design that can't be modified.
The basic idea now is to have two 4X8 beams sitting atop some massive 12X12 columns that I found in a stack at the lumber yard. These two 4X8 will span a length of about 22 feet seperated by about 4 inches and have three of these columns, two supporting them on either end and one in the middle, as bases. These beams which will support the rafters (I'm not sure what the proper term is) will have the fancy ends cut on them and all the 4X6 rafters that lay on top will also have fancy ends, then run into the house and be supported within the wall. I'm going to put the 4X6's on 24 inch centers, then cover the whole things with a 75% shade cloth on a retractable cable system to have it all open if desired. If I don't do the shade cloth I will cover it permanently with bamboo strips to let a little sun through. Oh, and evrything will be anchored together with hip joints, and long lagbolts from the top so you don't see any hardware.
Hope that wasn't too confusing, it makes sense in my head 8-)
Good Luck,
Brian
Thanks Brian. You don't have to contend with snow, I take it. I live in NH, so my roof will have to be something more substantial (e.g. metal, shingles). When you do finish it please post pictures...Good luck...Regards,
Buzzsaw
"Don't ask yourself what the world needs. Ask yourself what makes you come alive, and go do that, because what the world needs is people who have come alive." Gil Bailie
Buzz,
SNOW, I'd love some of that right about now. It's about 38 - 40 degrees here right now (that's 100 degrees farenheit for you american folks) and the humidity is nut's because it's been raining in the late afternoon for the last couple of days.
In the wintertime here it has NEVER gone below zero, it's really a great climate, but the summers are tough. It's hurricane season here now so if my communication to you all suddenly goes away, it probably means we're off the grid until they fix everything. I don't know how many of you have ever lived through a hurricane, but it's a very humbling experience, nature's power is truly awesome.
I'll post some pics if the wind doesn't blow everything away 8^)
Take Care,
Brian
http://forums.taunton.com/tp-breaktime/messages?msg=51421.3
You had asked another Knots reader if he had any pictures of sculpted beams in a porch roof assembly. Although this (link above) is not a porch roof, it uses pattern-cut ends on beams.
Unless you're the lead dog, the view just never changes.
This forum post is now archived. Commenting has been disabled