Fitting braces to the first frame

The first two braces fitted

I started to fit the braces to the rear frame 2 weeks ago (on 15.04.12). Although I expected this to be quite a difficult task I was relieved to find that once started this was not as complex as I had imagined. To mark the joints I clamped each brace in position and used a plumb bob and spirit level to mark out, working on the principle that if I cut the end of the timber square I could use this as the datum edge to mark the tenons. Any irregularity in squareness of the sole plates and wall posts could then be adjusted for. Once the tenons were cut I marked the position of the mortices. 

The biggest disappointment over this period was the weather. I was able to fit three braces in the first week but heavy showers during the second week meant that most of the week was spent with the frame covered with the tarpaulin. 

I was able to cut the fourth brace to shape at the beginning of the week - mostly working under the tarpaulin - but unfortunately I had to wait until 27.04.12 to fit the final brace. 

The fourth brace cut 

All four braces fitted

The process of fitting the braces meant that I had to assemble, dismantle and reassemble the frame and whilst doing this I marked and drilled the holes for the pegs. When assembled for the last time I temporarily pegged a few joints although the frame was very stable without any pegs. Most of this frame should now be able to stay in place but I will have to remove the wall plate when I start to fit the principle rafters - however this is a little way off at the moment.

Temporary pegs in place

A significant milestone has been reached and the next task will be to start to mark and cut the joints for the front frame. (I am pleased that I have already cut the wall posts to length).      

Sole plates

Sole plate tenons 
offset to allow space to fit the vertical wall posts

One of the challenges of building my shed was the space available to work in. Having to store some of the timber on the concrete base leaves little space to work. In the first few weeks I spent a lot of time just moving timber around. To give me more space I decided that erecting as much as of the frame as I could as work progresses would be a way to give me more space to work. The downside of this strategy is I have to take the frame down at certain times but it does mean I can layout for cross braces, etc. more easily than trying to do this in the usual way (in the horizontal plane).


I therefore decided that I needed to layout the sole plates and cut the joints in these timbers. Cutting the joints was relatively easy but I was rather concerned about the assembly of these simply due to the weight of the timbers. I can just lift one end of the 150mm square 4 metre long beams.


I put the sole plates together in the week of 9th April 2012 and, much to my surprise the assembly of these was very easy with the joints fitting just right first time. It was interesting that once in position it felt like the shed was beginning to take shape.

The sole plates assembled 

Braces

A key attraction of traditional timber frame buildings are the wall braces that ensure the frame remains fixed and prevent lateral movement of the frame. The curved timber was supplied but a lot of work was required to shape to a suitable size.  At first I thought about asking a local saw mill to cut to shape on a band saw.  However when I thought about this I realised this was taking an easy option and I really had to do these by hand. 


I purchased an adze and draw knife and set to work. I had eight large braces to cut and I had cut 7 by 23.04.12. I usually worked on these when the weather was less good and I could work in the garage or - more recently - under the tarpaulin.

Brace ready for using the adze

Brace partially cut with the adze

Finishing the curve with the draw knife
(with help from Miranda)

Brace finished

Retirement and mortice and tenon joints

Cutting a tenon

Part of my plan with the shed was to have started working on the shed so I had a major task to work on when I retired, without having to think too much about what I would do.  When I finished work on 22.02.12. I had just begun to cut the mortice and tenon joints for the first four wall posts. After a 3 day break in Cornwall I was ready to press on and get the first frame finished as soon as possible. The weather was good at first and by the end of March I had cut the joints for the first frame and was ready to see how it went together. 


The pulleys were essential to enable me to get the wall plate onto the four wall posts - much to my surprise everything looked OK.

Wall post tenons

Wall post in position in the sole plate

The rear frame in position

Starting to mark and cut

Before I could begin to mark out for the first frame I needed to make four sawing horses to lay the frame out on and cut the timber. The weather wasn't too good so I spent the time in the garage making these.


In January 2012 I began to cut the wall posts to length for the front and rear frames and also the sole and wall plates. Although I was able to use my portable circular saw to help a little with this task it was not large enough to cut any timber right the way through so I had to finish with a hand saw. 


To cut the sole plates (150mm square) I used the power saw to cut as deep as I could on each side and then finished off with the hand saw - finally planing the ends square. Marking and cutting the mortice and tenon joints was not too difficult but checking for fit was harder as gravity meant that the weight of the post would easily wedge the post tight making it difficult to get out. I soon learnt and became more proficient at cutting the joints to fit a little more easily.


As I handled the timber more I realised that by the time I got to the roof I would need some scaffolding and pulleys to lift the roof timbers into position. I ordered some scaffolding to make a simple frame and also two double pulleys and rope - I also realised that this would provide me with the possibility of constructing a shelter to work under when the weather was less good. 

Assembling the scaffolding into two A frames was the easy bit - fortunately my friend Howard came round just at the right moment to help me get the top bar and brace in position. Progress was being made.

Arrival of the timber

After asking around I ordered the timber from Anton Coaker who has a saw mill at Sherberton on Dartmoor (visit http://www.anton-coaker.co.uk/). There was a wait for delivery (which was very fortunate as it gave me time to finish the foundations, as I was going to have to store at least some of the timber on the concrete base). 


The timber was delivered to the top of the playing field and the driver and I unloaded it onto a stack just inside the fence. When the lorry arrived I was rather surprised at how much timber there was and when we began to unload I realised just how heavy it was. 


To get the timber from the field to the garden I used a sack barrow - the longer timbers I roped to the barrow and lifted the other end - fortunately it was down hill to the garden although manoeuvring the long lengths into the garden was difficult. My neighbour, Ian, kindly helped me with the two 4 metre long 150 x 150 mm sole plates - the rest I moved myself. It took 7 hours to unload the lorry and move the timber into the garden - it was getting dark as I was finishing.


The following day I sorted the timber out and ended up with two stacks - one stack of timber for the front and rear frames, sole plates and braces (all on the concrete base) and another stack with the remainder in another part of the garden.

Part of the second stack

The base was complete - the timber had arrived - I could now start marking out and cutting.

The beginning

The site

So many people have taken an interest in my shed that I thought it made sense to keep everyone up to date through my blog.


I began thinking about building a shed about two years ago and in the process of designing it and applying for planning permission I decided to make a green oak frame using (mostly) traditional tools and techniques. 


The shed is 4 metres x 3 metres (the largest I could make in the space I have available in my garden). In retrospect I am rather glad it isn't any bigger as I would have had great difficulty lifting and moving the longer timbers.


I started laying the foundations in October 2011. The nearest the aggregate could be delivered was to the adjacent playing field (about 150 yards from my garden). Two bags (1 tonne each) were brought to the garden by a friendly farmer. To move the contents of the third bag I used the wheelbarrow to transport it across the field. 

My neighbours, Helen and Andy, are currently renovating a barn and they kindly gave me some hardcore from the site (approximately 200 yards from my garden). More hard work using the wheelbarrow!

With the use of a hired cement mixer I completed the foundations over three days.