Make the Curved Braces for the Three Gable Timber Frame style Pavilion
For this structure I designed two similar braces. For the inside corners I have a small curved brace. These are made from 3″ thick stock. Connor’s neighbour, BJ, was kind enough to let us use his shop to make the braces.
Beforehand, I made two plywood patterns for the brace designs. Here Connor is tracing the outline of the smaller brace onto stock. And trying to avoid any knots if he can.
He cuts two opposing 45 degree angles on the miter saw.
Finishing each cut with a hand saw where the circular blade didn’t reach.
Sanding the Braces
I took these to the band saw to cut the curves.
Then over to the sander to smooth the rough spots.
The outside braces are slightly larger. As before, the pattern is traced and the angles cut. There’s a small 90 degree cut in the corner, and that’s done on the miter saw as well.
These too are taken to the bandsaw to cut the curves then on to the sander for finishing.
Stops are clamped to the drill press table and it’s tilted 20 degrees. A forstner bit is used first to countersink the head of the lag bolt that will secure the brace to the posts and beams.
Then the bit is swapped out, and holes drilled clean through the brace.
After staining, the braces are held in place and holes drilled with a long bit into the beam, then into the post. Long galvanized lag bolts are run in with an impact driver. Then hand tightened with a socket wrench to prevent thread rip out.
The larger outside braces are easier to install with some help.