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First, a 3d design is created using our client's plans and ideas. By clicking on the image to the left, a 3d .pdf file can be downloaded and opened using Adobe Reader 9. A similar file is created for every one of our clients based on their individual custom design. |
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Estimating
Once preliminary drawings are provided by our clients' architects or after we complete a 3d preliminary design, the project goes to Richard, our estimator. He will often do a sketch then will take off a material list for pricing. |
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When the price has been approved by our client and a deposit received, we prepare detailed shop drawings. The process takes place in two parts. First preliminary drawings are provided for engineering review and material order. Second, we detail all the individual parts and their joinery for the fabrication team to use in the shop.. |
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Raw Material
After a timber order is placed, raw beams are sent to us from the sawmill. The photo to the left shows rough timber that is stacked in our shop and ready to be laid out. |
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Layout
All of our frames are laid out and cut by hand. We still feel that it is the best way. Pencil marks are drawn on each piece by the layout person, showing the timber framers where each cut is to be made. Every beam is oriented for crown, appearance (the best side is placed in the most visible location) and strength. |
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Fabrication
The photo to the left shows timbers at the cut stations ready to be fabricated. |
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Here, Mike is punching a mortise into a timber. He has double checked all of the layout person's marks for accuracy and will cut the beam to length and do all of the notching. |
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Help with the Plans
Once in a while Kramer (the poodle) gives us some help with the plans. |
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A sixteen inch timber saw is used to cut the large beams. |
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Here, Kellin is cutting and finishing precise joints into a round timber column. Even though the column is irregular in shape, the joints have to be exactly positioned off of its center for the other parts of the final timber frame to fit and work together. |
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Hand Craftsmanship
Mike is using a razor sharp chisel to precisely hone the end of a timber to the exact computer generated specifications.. |
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Band Saw Mill
Most of the timber we use is sawn at mills that we have been buying from for years. But, occasionally we re-saw timber ourselves for small jobs, or use our precision band saw mill to rip angled faces on beams. Here, a round column is being shaped. |
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Drilling
Mike is using a hand held drill press to cut peg holes into the timber. |
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Detailed Work
Smaller saws are used for cutting the detailed joinery. |
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Cleaning the Timbers
After the timbers are cut, they are cleaned before stain is applied. Here, Todd is using a whisker wheel to clean up rough sawn timber. |
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Sanding
Smooth timbers (S4S - Smooth 4 Sides) are sanded before finishing. MJ is finish sanding arches in this photograph. |
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This stack of douglas fir beams is ready for stain or urethane to be applied. All the joints are cut, the peg holes have been drilled and each timber has been individually marked on the end according to its exact location in the frame. |
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Here, natural minwax stain is being applied to rough sawn hemlock timbers using a roller. Each beam has stain applied to all four sides and in all the pockets and joints. |
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These arched braces are drying after receiving a coat of dark stain and a coat of urethane. Notice that all surfaces of the brace have been sealed. The final coat of urethane protects the timber and gives a nice finish. |
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When trusses are less than ten feet tall, we can assemble them in the shop and ship them over the road, ready to be installed. When they are more than ten feet, we pre assemble them to make sure that all the joints fit properly before we ship them to an outside contractor. If we are installing the trusses, we do the final fit on the jobsite. |
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Post and Beam Kit Ready to Ship
Finished douglas fir timbers are packaged, banded, labeled and ready to ship. |
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Assembled Trusses for Shipment
Assembled heavy timber trusses are being prepared for shipment. Note the paper wrapped lumber packages in the background which are waiting to be loaded on a tractor trailer. |
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Beam Packages Loaded on a Truck
A forklift places paper wrapped beam packages on a tractor trailer truck for delivery to a job site. |
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Pre-Assembled Bents Ready to Raise
This is a great photograph showing how timber frame "bents" are pre-assembled on the deck before the raising. These bents are forty feet wide and over thirty feet high. |
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Raising a Timber Frame
On the day of the raising, a crane lifts the bents into place. Connectors, joists and purlins are dropped into place between the bents. Notice the workman standing on the upper part of the frame in the background where joists and purlins have already been installed. |
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A heavy timber wood truss is lifted off a stack of trusses by a crane. It will be flow to its position sixty feet up. |
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When a bent is being positioned into place, people hold each post to line them up into their final places. Come-alongs and steel guy wires are used to steady and brace the bent while the connecting pieces are installed. |
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A timber truss with steel gusset plates is being lowered into place by a crane. Richard and Jason are preparing the pockets in the column to receive the truss. Once it is fitted, it will be bolted and pegged. |
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A Rafter Being Installed
A timber rafter is being placed between bents. Notice the notches in the bottom of the rafter and in the top of the bent. |
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The timbers being raised in this photograph are for a Fresh Air Fund Dining Hall in Fishkill, NY |
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Steel gusset plates are sometimes used to join timbers when the forces are large, or when an architect like the look of black steel plates. These gussets have a stiffened shelf that will support a connecting rafter. |
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This photo shows timber framed bents stacked on the ground as well as bents that have been lifted into place and connected together with wooden beams. |
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The last rafter set is being lowered into place in this pretty little barn in Vermont. Click here to see a YouTube video of the barn raising. |
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A photograph of a finished frame after the raising. |
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Beautiful Porch Timbers
The finished timbers of a very beautiful porch post design by Jeremy Bonin. |
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Finished Rough Hewn Timber Frame
A photograph of a rough hewn (hand hewn) timber truss after it was installed. |
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