Mar 222018

Today was the day of working out and implementing a method that will produce a set of two rafters, that will form the diagonal hip support beam from the point of the C wall and down to the gutters in the corner of the porch roof over our Front Door.
But first, we took out our “C7” rafter we made last night and got that up installed, glued and screwed to await for the next parts to made.

So back in the workshop, the first task was to set up the big planer machine so we could pass through the top edge of the manufactured hip beam and get two different sloping angles along the length. We made a wooden jig out of plywood and some blocks of wood to form a sloping support at the required 55.6 degrees angle, to guide the timber into the planer. The other angle we needed was a much shallower angle at 10.8 degrees and we could use the metal fence mechanism that came with the planer itself.

Two Diagonal Hip Rafters Almost Completed


We made a test piece which we cut in half with a 32 degree angle on our chop saw. Then proceeded to cut a very, very shallow angle by hand, measuring at 17 degrees, using lots of muscle power and pencil lines to remove a large thin slice off.
Two Diagonal Hip Rafters Almost Completed


(As you can see from the technical drawing above, it is quite a complicated finished piece of work)

To check our finished test piece, we took it outside to compare it against the C7 rafter and it’s not too bad, not bad at all, if we are allowed to say so!!
After lunch, it was time to tackle the big job of taking our 5.5metres long timber and getting it through the planer machine but we had some difficulties in getting it to just plane at all in the first place. The nature of the planning machine, as it is designed to do, is to plane flat any piece of timber and remove curves and other deviations and our long timber pieces had a slight curve in them. We didn’t mind these slight warp off the true straight line but it meant that the planer couldn’t do the work we wanted done! So back to plan A, which was to use our mobile electric planer instead, and after clamping our rafter to the edge of the work-tables, we managed to get the two sloping angles cut into the top edge of the two rafters.
Finally, to finish off the work for the day, we got our Bevel Slicing saw machine out and set this up to cut that very, very shallow angle, using the old templates (re-adjusted to fit these new rafters) and proceeded to slice the ends off the top of the rafters.

Two Diagonal Hip Rafters Almost Completed


This almost concluded the work on these rafters, tomorrow, w we will cut a little bit off at the top ends and then cut the Bird’s mouths in at the exact measured distance and this would finally see the completion of making these complicated rafters and get them installed out there!! Phew!

 Posted by at 5:56 pm
Mar 212018

This morning in lovely hot sunshine and no winds, we concluded the job of covering up the gable end of the Front Door extension that will have the porch coming out.

Front Door Gable Wall Completed and First C rafter Created


We used up our remaining pieces of cement boards and created lots of triangular left-over parts in return, some of which will be used on doing the gable end up inside the Side Door Porch later on.

After lunch, we set out to create the first rafter to form the “C” section of the roof, this being the steeply pitched roof on the front of the porch over the Front Door and Entertainment room area of the house. we had to reposition the guides on our Bird’s Mouth gig so it will cut the 61 degree angles for the end and the notch bitten out to form the Bird’s Mouth itself.
We also had to make an extended angled support fence on our chop bench saw so we could slice the very acute angle off the end of the timber. The machine can only go up to 45 degrees but we needed to get up to 61 degrees, hence the funny extra adaptations added to the chop saw!

Front Door Gable Wall Completed and First C rafter Created


After several test runs to prove to ourselves that things are coming out correctly, we went out to climb to the top of the C wall to measure the distance from the very top point and down to the new horizontal beam out on the arms of the porch. We double checked this measurement several times and then prepared for real, a length of 89mm CLS timber and proceeded to slice and chop it down to the required size. As it was getting dark, we took it back outside to see how well it fitted in the real world and hey presto! It Fitted!! Grin!

Tomorrow, we will glue and screw this rafter, which is actually labelled “C7”, up in place and then work on the even more complicated piece, the two diagonal Hip rafters that also goes from the top point of the C wall and down to each corner of the porch roof but they have two sloping edges on the top surface, a double cut ends and a bird’s mouth in it too of course! Phew!

 Posted by at 6:03 pm
Mar 152018

This morning, we buried three sets of concrete blocks to support three legs which will soon be in place to brace the Front Porch. We didn’t put up the new 7.6metres (25feet) long beam as the glue was still slightly tacky (the temperature isn’t warm enough for speedy curing) so we left it alone to […]

 Posted by at 5:28 pm
Mar 152018

After lunch, we thought it would be a good idea to make another template jig to help with the task of slicing off the tops off the cement boards of the walls that protrudes up between all the rafters around the building. The router machine is guided between the two lines of the plywood support […]

 Posted by at 3:35 pm
Mar 142018

After we had finished the rafters, we got on with making the long beam that will form the porch for the Front Extension, overhanging the front door and Entertainment window. It is three layers of 89mm CLS timber and we used our brown silicone glue instead of the more usual PVA white glue because the […]

 Posted by at 6:12 pm
Mar 142018

Today, in some lovely sunshine but with a chilly wind, we concluded the installation of the five “N” rafters and twelve “K” rafters! This, finally, at last, sees the end of manufacturing and installing of the full sized rafters all over the whole roof, adding up to a total of 176 rafters!! One Big Phew! […]

 Posted by at 4:33 pm
Mar 132018

The man with the smelly lorry came this morning to do our regular emptying of our Septic Processing Tank. It is almost a year since the last one. We then did some pressurised washing inside the chamber and down the pipes going off to our leech field and get everything ready for another year. In […]

 Posted by at 2:44 pm