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Cedar Driveway Gate

18K views 21 replies 10 participants last post by  clin 
#1 ·
Design and Preparation

Wood Tints and shades Tent Flooring Metal


So, the old ugly driveway gave in after some strong winds. I've been planning on replacing it with something nice for about five years. I guess the time is now.

Rectangle Parallel Slope Grass Drawing


I drew up some design ideas in Sketchup and my wife and I agreed on a design. I took a lot of inspiration from English driveway gates. It will be built of knotty cedar to maintain a rustic look, keeping in line with the house. The space below the arch will be some custom welded iron work (my father-in-law is quite the expert).

The frame stock will be 2-1/8 inch thick. The joints will we traditional mortise and tenon with drawbore. I'm hopeful to have this finished in a month….......

Hope u enjoy following along.
 

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#2 ·
Purchasing and Preparing the Stock

A trip to the Lumber store took about three hours longer than expected. My wife and I needed to sift through nearly all the cedar in stock to get some that were workable. Almost wanted to give up and go to clear cedar or redwood. None-the-less, we prevailed and took the rough stock home.

Wood Flooring Floor Wood stain Plank


To get the 2-1/8 thickness, I need to laminate a piece of 1Ă—6 stock to a piece of 2Ă—6 stock. I tried to select the pieces to compliment each other.

Wood Musical instrument Wood stain Outdoor furniture Hardwood


I cut all the stock to rough dimensions on my newly built miter station.
 

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#3 ·
Laminating, Laminating, Laminating

This step took roughly a week and a half. Couldn't clamp more than two a day as clamps were in short supply.
Wood Floor Flooring Engineering Hardwood


Each board was planed on one side and laminated together one piece at a time with Tightbond III

Wood Rectangle Table Flooring Floor


Lott's of glue

Wood Flooring Hardwood Art Event


Lott's of clamps!

Liquid Fluid Bottle Plastic bottle Shelving


Did I mention Glue? I used about a half-gallon. I must say that the Rockler glue roller was life saver. I highly recommend it for applying large amounts of glue quickly.
 

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#4 ·
Creating the Arc Template

In the midst of jointing and planing the stock, I took a bit of time to create the template for the arch. Eventually I will use it to draw the arch on the boards and will use a pattern bit to finish up the edges. I posted the second go around as I messed up the measurements on the first.

I used CAD to determine how the arch will fit and the dimensions.

Rectangle Slope Font Parallel Pattern


Using the two stick method (which I learned from other LumberJocks) I drew the top of the arch.

Wood Road surface Flooring Floor Beige


Cut outside the line with the jig saw.

Hood Wood Flooring Automotive exterior Floor


Sand to final shape.

Table Desk Wood Computer desk Floor


Copy the bottom line exactly 5 inches apart using the combination square and a sharpie.

Wood Floor Flooring Triangle Automotive exterior


Cut and sand to final dimensions.

Wood Flooring Floor Audio equipment Hardwood


Voila! An arch template.

Wood Floor Flooring Hardwood Lumber
 

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#5 ·
Dimensioning the Stock

The crucial step of dimensioning the stock was a physical and tedious process. I'm in decent shape, but wasn't expecting such a workout. Each piece needed to be planed to 2-1/8" thickness and be perfectly square so that the joints line up. Quite a task on long heavy pieces.

Wood Natural material Rectangle Hardwood Flooring


After the laminating was finished, the stock was made flat and square.

Wood Floor Flooring Engineering Machine tool


The length of the wood made it a challenge for my 6 inch Jointer.

Food Ingredient Cuisine Dish Kitchen appliance


Planer and dust collector got quite a workout. I emptied the bin three times.

Table Wood Tool Workbench Writing desk


Final trimming on the new miter station.

Wood Wood stain Hardwood Tool Lumber


All set to the specified dimensions. On to some fun.

Rectangle Wood Road surface Wood stain Flooring


Wood Rectangle Composite material Flooring Hardwood


Now she's starting to look like a gate.

Next step joints!
 

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#6 ·
Dimensioning the Stock

The crucial step of dimensioning the stock was a physical and tedious process. I'm in decent shape, but wasn't expecting such a workout. Each piece needed to be planed to 2-1/8" thickness and be perfectly square so that the joints line up. Quite a task on long heavy pieces.

Wood Natural material Rectangle Hardwood Flooring


After the laminating was finished, the stock was made flat and square.

Wood Floor Flooring Engineering Machine tool


The length of the wood made it a challenge for my 6 inch Jointer.

Food Ingredient Cuisine Dish Kitchen appliance


Planer and dust collector got quite a workout. I emptied the bin three times.

Table Wood Tool Workbench Writing desk


Final trimming on the new miter station.

Wood Wood stain Hardwood Tool Lumber


All set to the specified dimensions. On to some fun.

Rectangle Wood Road surface Wood stain Flooring


Wood Rectangle Composite material Flooring Hardwood


Now she's starting to look like a gate.

Next step joints!
I'm really looking forward to seeing this come together. It feels like getting to this stage is half the battle.
 

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#9 ·
Whats in an arc

I'm gonna focus a bit on how I made the arc as it is a little more complicated than the rest of the process.

Wood Floor Flooring Hardwood Lumber


To get the arc to the right proportion, I needed to laminate two pieces of wood. Here, I am laying out where the arc will fit using my template.

Furniture Table Wood Musical instrument accessory Wood stain


I'm used biscuits for alignment and to hopefully protect against de-lamination. It's important to lay out where the biscuits are so that they don't show when the arc is cut.

Table Wood Engineering Tool Automotive exterior


Biscuits are cut.

Wood Flooring Floor Gas Engineering


Laminating…

Wood Naval architecture Engineering Varnish Composite material


Wood is dimensioned and the lines are re-laid out.

Wood Floor Audio equipment Flooring Gas


Tenon partially cut on the band-saw.

Easel Wood Wood stain Plank Hardwood


A jig to router out the tenons.

Wood Floor Flooring Fixture Hardwood


Tenons after routing.

Table Wood Floor Flooring Workbench


Cut out on the bandsaw.

Wood Floor Flooring Gas Bumper


Trimming the shoulder.

Table Wood Electrical wiring Flooring Audio equipment


Now the template comes back into play. I use it as a pattern. I use a pattern bit on the router to clean up the
edges.

Wood Flooring Floor Gas Hardwood


The pattern bit only gets so far.

Table Wood Flooring Floor Workbench


Flip it and finish it up with a flush trim bit.

Table Wood Shipping box Tool Workbench


Now I have an arc that is ready to be fitted to the mortises.

Up next…Mortises.
 

Attachments

#10 ·
Whats in an arc

I'm gonna focus a bit on how I made the arc as it is a little more complicated than the rest of the process.

Wood Floor Flooring Hardwood Lumber


To get the arc to the right proportion, I needed to laminate two pieces of wood. Here, I am laying out where the arc will fit using my template.

Furniture Table Wood Musical instrument accessory Wood stain


I'm used biscuits for alignment and to hopefully protect against de-lamination. It's important to lay out where the biscuits are so that they don't show when the arc is cut.

Table Wood Engineering Tool Automotive exterior


Biscuits are cut.

Wood Flooring Floor Gas Engineering


Laminating…

Wood Naval architecture Engineering Varnish Composite material


Wood is dimensioned and the lines are re-laid out.

Wood Floor Audio equipment Flooring Gas


Tenon partially cut on the band-saw.

Easel Wood Wood stain Plank Hardwood


A jig to router out the tenons.

Wood Floor Flooring Fixture Hardwood


Tenons after routing.

Table Wood Floor Flooring Workbench


Cut out on the bandsaw.

Wood Floor Flooring Gas Bumper


Trimming the shoulder.

Table Wood Electrical wiring Flooring Audio equipment


Now the template comes back into play. I use it as a pattern. I use a pattern bit on the router to clean up the
edges.

Wood Flooring Floor Gas Hardwood


The pattern bit only gets so far.

Table Wood Flooring Floor Workbench


Flip it and finish it up with a flush trim bit.

Table Wood Shipping box Tool Workbench


Now I have an arc that is ready to be fitted to the mortises.

Up next…Mortises.
Nice , I like it. Looking really good.
 

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#11 ·
Cutting the Mortises

Now that everything is laid out flat and square, the mortises need to be cut.

Wood Wood stain Floor Flooring Plank


Wood Workbench Engineering Machine Tool


I used to have a desktop version of the mortiser. The full size powermatic makes the job much easier.

Pneumatic tool Handheld power drill Wood Drill Hammer drill


Final cleanup with the hammer and chisel.

Next time tenons.

Here's a little teaser.

Wood Flooring Road surface Floor Wood stain
 

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#12 ·
Tenons and Some Details

Last time was the mortises and now the tenons. I had a pretty rough time getting these cut. The biggest issue was getting the shoulders straight all the way around. The first technique was with a router and a jig.

Wood Saw Wood stain Tool Hardwood


For the flat.

Wood Floor Workbench Flooring Hardwood


For the edge.

Aircraft Wood Airplane Vehicle String instrument


Having never worked with such large joints, this turned out to be incredibly tedious and I couldn't get the shoulders to line up. I tried table saw, hand saw…. wasn't working. So, needed a new tool.

Wood Table Hardwood Automotive exterior Flooring


Enter Stanley.

Hand tool Wood Metalworking hand tool Tool Ball-peen hammer


I also sharpened up my chisels and block plane. This is the first time I've really used hand tools for fitting. Turned out to be a life saver.

Wood Office supplies Office equipment Engineering Typewriter


Eventually I gave up on the router and switched to the bandsaw, using hand tools for all the fitting.

Table Wood Wood stain Flooring Floor


With everything lined up!

Wood Rectangle Wood stain Hardwood Natural material


Drew out the top lines.

Wood Saw Table Flooring Workbench


Cut on bandsaw.

Wood Gas Hardwood Machine Machine tool


Sand to Shape.

Wood Hardwood Wood stain Shelf Surfboard


Pretty top curves.

Sky Cloud Wood Road surface Door


Now we have a Frame!
 

Attachments

#13 ·
Tenons and Some Details

Last time was the mortises and now the tenons. I had a pretty rough time getting these cut. The biggest issue was getting the shoulders straight all the way around. The first technique was with a router and a jig.

Wood Saw Wood stain Tool Hardwood


For the flat.

Wood Floor Workbench Flooring Hardwood


For the edge.

Aircraft Wood Airplane Vehicle String instrument


Having never worked with such large joints, this turned out to be incredibly tedious and I couldn't get the shoulders to line up. I tried table saw, hand saw…. wasn't working. So, needed a new tool.

Wood Table Hardwood Automotive exterior Flooring


Enter Stanley.

Hand tool Wood Metalworking hand tool Tool Ball-peen hammer


I also sharpened up my chisels and block plane. This is the first time I've really used hand tools for fitting. Turned out to be a life saver.

Wood Office supplies Office equipment Engineering Typewriter


Eventually I gave up on the router and switched to the bandsaw, using hand tools for all the fitting.

Table Wood Wood stain Flooring Floor


With everything lined up!

Wood Rectangle Wood stain Hardwood Natural material


Drew out the top lines.

Wood Saw Table Flooring Workbench


Cut on bandsaw.

Wood Gas Hardwood Machine Machine tool


Sand to Shape.

Wood Hardwood Wood stain Shelf Surfboard


Pretty top curves.

Sky Cloud Wood Road surface Door


Now we have a Frame!
Great project
 

Attachments

#18 ·
Chamfer, Channel, Weep Holes, and Drawbore

It's been awhile since I've posted on this project to I'd like to catch up with the progress. Last time I posted, another lumberjock mentioned a concern with a lack of diagonal bracing. I've been seriously looking into altering the design to make sure I cover this issue. I posted in the forum and received some pretty great feedback. Here is the link if anyone is interested: http://lumberjocks.com/topics/167994

So moving on, I needed to do some detail work the edges.

Wood Flooring Floor Hardwood Gas


I used a chamfering bit to get a good consistent edge.

Wood Rectangle Flooring Floor Hardwood

Wood Rectangle Flooring Wood stain Hardwood

Using a slotting bit and a router I cut a 3/8" deep channel to accommodate the vertical slats

Next, I needed to drill some weep holes in the bottom to allow the channels to drain

Wood Floor Flooring Gas Composite material


I started the holes on the drill press to get them straight. I finished with the hand drill and a long bit.
Wood Tool Floor Flooring Hardwood

I cleaned the top and bottom of the holes with a countersink.

To make the Joints as solid as a rock, I decided to use drawbores.

Table Wood Office supplies Pen Ball pen


Laid out the holes.
Table Wood Workbench Engineering Toolroom


Using my scrapped together setup, I drilled 3/8" holes with a bradpoint drill bit on the drill press.

Wood Tool Wood stain Floor Hardwood


I offset the holes on the tenons 1/16" towards the shoulder.

After 32 holes , it's getting closer.
 

Attachments

#19 ·
Chamfer, Channel, Weep Holes, and Drawbore

It's been awhile since I've posted on this project to I'd like to catch up with the progress. Last time I posted, another lumberjock mentioned a concern with a lack of diagonal bracing. I've been seriously looking into altering the design to make sure I cover this issue. I posted in the forum and received some pretty great feedback. Here is the link if anyone is interested: http://lumberjocks.com/topics/167994

So moving on, I needed to do some detail work the edges.

Wood Flooring Floor Hardwood Gas


I used a chamfering bit to get a good consistent edge.

Wood Rectangle Flooring Floor Hardwood

Wood Rectangle Flooring Wood stain Hardwood

Using a slotting bit and a router I cut a 3/8" deep channel to accommodate the vertical slats

Next, I needed to drill some weep holes in the bottom to allow the channels to drain

Wood Floor Flooring Gas Composite material


I started the holes on the drill press to get them straight. I finished with the hand drill and a long bit.
Wood Tool Floor Flooring Hardwood

I cleaned the top and bottom of the holes with a countersink.

To make the Joints as solid as a rock, I decided to use drawbores.

Table Wood Office supplies Pen Ball pen


Laid out the holes.
Table Wood Workbench Engineering Toolroom


Using my scrapped together setup, I drilled 3/8" holes with a bradpoint drill bit on the drill press.

Wood Tool Wood stain Floor Hardwood


I offset the holes on the tenons 1/16" towards the shoulder.

After 32 holes , it's getting closer.
Looking forward to the final product. Great project!
 

Attachments

#20 ·
Vertical Slats

I decided to go with pre-milled tongue and groove slats from the lumberyard.

Sky Cloud Plant Automotive tail & brake light Vehicle


They came in 10ft lengths so they were cut to length on the miter saw.

Wood Floor Flooring Hardwood Wood stain


The backs were really rough so I ran them through the planer. The channels were a little small so I thinned the edges of the slats where they fit into the channels with a block plane.

Cabinetry Wood Table Hardwood Workbench


I tried to match the color and grains as closely as possible to each other.
 

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#21 ·
Diagonals

After some discussion on diagonal bracing, I decided to go with 3/4 inch diagonals that fit flush with the rails behind the back of the panels. The diagonals were to be put in compression.

Wood Rectangle Flooring Wood stain Plank


After another trip to the lumberyard and dimensioning with the planer, jonter and table saw.

Wood Tool Flooring Floor Hardwood


Built some "jackstands" to get the gate to a better working height.

Wood Boats and boating--Equipment and supplies Composite material Automotive exterior Plank


Laying out the geometry.

Wood Engineering Hardwood Tool Machine


Cutting on miter saw.

Wood Tool Gas Hardwood Machine tool


Cut rabbets with the router.

Wood Table Wood stain Hardwood Workbench


Chamfer with router bit and match end grain chamfer with block plane.

Wood Engineering Machine Gas Machine tool


Cut groove with router and stop blocks. Needed to make fillers in the channel for the bearing to ride against.

Wood Gas Wood stain Hardwood Plank


Match insertion angle with cutoffs and a chisel.

Wood Workbench Engineering Hardwood Machine tool


Final fitting with block plane and shoulder plane.

Table Wood Wood stain Plank Hardwood


Up next: Assembly
 

Attachments

#22 ·
Diagonals

After some discussion on diagonal bracing, I decided to go with 3/4 inch diagonals that fit flush with the rails behind the back of the panels. The diagonals were to be put in compression.

Wood Rectangle Flooring Wood stain Plank


After another trip to the lumberyard and dimensioning with the planer, jonter and table saw.

Wood Tool Flooring Floor Hardwood


Built some "jackstands" to get the gate to a better working height.

Wood Boats and boating--Equipment and supplies Composite material Automotive exterior Plank


Laying out the geometry.

Wood Engineering Hardwood Tool Machine


Cutting on miter saw.

Wood Tool Gas Hardwood Machine tool


Cut rabbets with the router.

Wood Table Wood stain Hardwood Workbench


Chamfer with router bit and match end grain chamfer with block plane.

Wood Engineering Machine Gas Machine tool


Cut groove with router and stop blocks. Needed to make fillers in the channel for the bearing to ride against.

Wood Gas Wood stain Hardwood Plank


Match insertion angle with cutoffs and a chisel.

Wood Workbench Engineering Hardwood Machine tool


Final fitting with block plane and shoulder plane.

Table Wood Wood stain Plank Hardwood


Up next: Assembly
Looking good. Any recent progress? I'm looking forward to seeing the finished work.
 

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