What tool for 6X6 detail cut?

**cabled** · 03-30-2008, 02:47 PM

I am getting ready to build a pergola/trellis over a deck using 6X6 cedar posts, 6X6 cedar horizontal beams, and various 2X cedar material for the "canopy" overhead. The customer has given me an example of several details for the ends of the horizontal beams (horizontal and parallel to the rear of the house), all starting as 16 footers. I would described the detail as an OG style. So, I am already thinking through what tool I will use to cut the detail. First choice would be a jigsaw, staying well off the line due to the blade wanting to walk. I have also used a reciprocating saw and had another worker "guide" the opposite side with a pair of pliers by holding the pliers on the non-cutting side of the blade. In that case, just stayed about 1/4" off the line and went at it with chisels and sanders from there. One other option could be to glue three 2X6's together, but just worried about them coming apart in the future, and fasteners showing all over the face of the beams would look awful. Thoughts/easier solutions? See attachment and thanks in advance.

**Lavrans** · 03-30-2008, 03:41 PM

How many 6x ends will you have to do? If it's just a couple I'd gang them together & go at it with a chainsaw & grinder :-) Finish off with chisels, you're done in 1/2 hour. You can also rough with a regular saw & finish with chisel, planes, grinder.

If you've got a template you can also work through from either side with a router & get down so you're just removing the center section by hand, and that leaves both sides nice and crisp. If you're using the same profile for your 2x ends you just use that template (the rough close, finish with a router method).

Last- a little 10" bandsaw on rollers. Or a bigger one: the bigger the saw the better the cut, but the more clunky to move around.

I'm sure someone else has a better method though :-)

**Overbuilders** · 03-30-2008, 04:00 PM

Originally Posted by cabled

Thoughts/easier solutions?

Are you wanting to cut the ends for the challenge or would you buy them pre-cut if you could?

**Overbuilders** · 03-30-2008, 04:14 PM

Originally Posted by cabled

I am getting ready to build a pergola/trellis over a deck using 6X6 cedar posts, 6X6 cedar horizontal beams, and various 2X cedar material for the "canopy" overhead. The customer has given me an example of several details for the ends of the horizontal beams (horizontal and parallel to the rear of the house), all starting as 16 footers.

My eyeballs locked onto the '6x6' posts and beams and completely missed that the canopy will be made from 2x material. Make a template guide for your router to clean up your jigsaw cut. Simple.

**JMS BUILDERS** · 03-30-2008, 04:20 PM

We do a fair amount of scrollwork out of diferant materials Our process is fairly simple ( By the way Great time to buy the PRAZI beam cutter if you dont have one already) 1 guy patterns and cuts, Gang cut as many as will fit either w/ the Prazi or a chainsaw with a 90* sled, measure cut the other side, or if you need an exact measurement (tie to wall?) Shape and sand the one side and cut the other side goes pretty quick if you get the system down

**JMS BUILDERS** · 03-30-2008, 04:21 PM

Originally Posted by Overbuilders

My eyeballs locked onto the '6x6' posts and beams and completely missed that the canopy will be made from 2x material. Make a template guide for your router to clean up your jigsaw cut. Simple.

Just caught that myself that would work also though.

**David Meiland** · 03-30-2008, 05:34 PM

Cabled, how's your tool budget? A timberframer's portable bandsaw is the most appropriate tool to my way of thinking, the smaller porta-bands will not cut 6x material. Oliver, Mafell, etc. Maybe there is one at a rental shop near you, or available for borrow from a lumberyard. I just went thru this, we needed to cut large arcs in 6x6. I used a chainsaw and Headcutter but it won't do that tight detail work you need.

**JMS BUILDERS** · 03-30-2008, 05:39 PM

Originally Posted by David Meiland

Cabled, how's your tool budget? A timberframer's portable bandsaw is the most appropriate tool to my way of thinking, the smaller porta-bands will not cut 6x material. Oliver, Mafell, etc. Maybe there is one at a rental shop near you, or available for borrow from a lumberyard. I just went thru this, we needed to cut large arcs in 6x6. I used a chainsaw and Headcutter but it won't do that tight detail work you need.

Ha! David you're # 3 Rick and I didn't read the post correctly either 8€

**Lavrans** · 03-30-2008, 06:11 PM

Originally Posted by cabled

One other option could be to glue three 2X6's together, but just worried about them coming apart in the future, and fasteners showing all over the face of the beams would look awful.

No, he's talking about cutting a detail in a 6x6. Probably also wants details on the 2x stock, but that's easier...

It sort of sounds like he's only got a couple 6x ends to profile, so it's not really cost effective to get the big equipment involved.

**Overbuilders** · 03-30-2008, 06:18 PM

I see scrollwork detail only on the right side of the canopy support beams. Very odd.

**JMS BUILDERS** · 03-30-2008, 06:38 PM

Originally Posted by Lavrans

No, he's talking about cutting a detail in a 6x6. Probably also wants details on the 2x stock, but that's easier...

It sort of sounds like he's only got a couple 6x ends to profile, so it's not really cost effective to get the big equipment involved.

Damn Lavrans you stiffled me again don't worry I will be back ha haah :)

FWIW i hate being wrong

**Lavrans** · 03-30-2008, 06:42 PM

Originally Posted by JMS BUILDERS

Damn Lavrans you stiffled me again don't worry I will be back ha haah :)

Stiffled? Stiffled? Why...

Speaking of which,

Ricardo, did you have a source for pre-cut 6x6 beams?

**rustynail** · 03-30-2008, 07:16 PM

we do alot of decorative corbel cuts and we have 2 Oliver Model 12M - 8" Portable Band Saws, we even do cutting for other builders. before I used a prazi and a belt sander if I just had to cut a few to match precuts, now we sometimes cut 300,400 even 600 corbel ends for o/h tails( that's y we have 2).http://www.flickr.com/photos/9138016@N03/2375876272/

http://www.timberwolftools.com/tools/kind/bandsaws.html

Russell

**Overbuilders** · 03-30-2008, 07:19 PM

Originally Posted by Lavrans

Ricardo, did you have a source for pre-cut 6x6 beams?

No, but I found several after a google search. Any large deck/fence supplier should be able to get them, also.

**Overbuilders** · 03-30-2008, 07:20 PM

Originally Posted by rustynail

we do alot of decorative corbel cuts and we have 2 Oliver Model 12M - 8" Portable Band Saws, we even do cutting for other builders

http://www.timberwolftools.com/tools/kind/bandsaws.html

Russell

Wow! Those are so cool...and so expensive!

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