I need help in building some outdoor post such as may be used on a large gazebo.
In the past and on other outdoor projects (porch railing, light post etc) I have used treated 4×4 or 6x6s then made the base bigger by using raised panels that wrap the post. The problem comes when I try to make the top cap molding (a series of moldings to blend the larger base to the smaller post) or put on the baseboard molding around the bottom of the base. The miters of the moldings soon separate and require that I go back with thin strips to slide into the gap (which can be 1/8″ wide) and then I trim and sand to match the molding. That looks okay once painted but still I continue to fight small gaps and it never looks neat. I have: used 3/4″, and 1″ material; treated wood, pine and most recently Spanish Cedar; glued and not glued; left ‘expansion gaps; painted all the wood first and still I have the gaps. I have considered not wrapping the molding over the panels by using thicker material that only wraps the treated post but I think they will move as much as the other wood.
Any assistance will be appreciated.
Edited 5/3/2006 3:07 pm ET by Captunseen
Replies
Captun,
Your troubles, I think, are a result of both design and material selection. Wood moves and any time the weather changes it is going to either shrink or swell. You want to use a material that is dry, rot resistent, and pretty clear. You also want to avoid miters and cross-grain parts if you want gap-free work. If the wood is dry you can build up the bases using wider peices of the same material with grain running all parallel. If you join the parts well and use an waterproof glue I would think this could work. But you still need to dry the wood first.
If you want a simpler solution, you could screw on vertical 2x2s all cut at 45 degrees at the tops to shed water. If these are rounded over on the edges the gaps will appear as part of the design. You'll have a thicker base without miters.
For more advise on this you might want to tlak to the guys in Fine Home Building) You could also consider the timber framer's guild sight (http://www.tfguild.org/ubbcgibin/ultimatebb.cgi) This is the link to the "Ask the Experts" forum there.
Wood is a natural material that has some beautiful properties. But you need to design with it's nature in mind and accept movement as part of the deal. Let it move.
Brian
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