Trengayor Wood Works

Water wheel re-build

2012-01-27T14:14:00.000-08:00

Its been in the pipeline for a few months now, but the timber has now arrived in the yard, and we're set to begin this most interesting project. Phase 1 is to re-construct the wheel, which was originally from a mill at Grampound. The cast iron rim and shroud sections have been reconditionned, as have the axle, hubs and bearings...but all the woodwork that makes the buckets will be from new air-dried oak boards. Assembly will have to be well thought out; slow, safe and methodical, with a few puzzles along the way to keep us sharp.

Phase 2 will be to build the flume that feeds the water into the wheel...again plenty of careful planning required to calculate flow rates and entry angles. The finished wheel will rotate at about 6 rpm and will drive a generator, feeding directly into the national grid. A perfect marriage of old and new technologies. I enjoy all of my carpentry projects, but these are the jobs I really dig.

Big ol' barn

2011-11-16T06:47:00.000-08:00

Paul's barn is one that I'd quite like for myself. I'm not sure what I'd do with it, but it wouldn't take me long to think of something. Unfortunately, I seem to earn a living making things for other people that I would quite like to keep for myself. One day....

More finished green oak timber frames in Cornwall

2011-10-27T10:40:00.000-07:00

This big 4 bay garage in Green oak and Larch is only 200 yards from our workshop just outside Falmouth, about as local as we could hope for, but somehow it's still taken me 3 months to go and take a picture of it. The customers are always happy for me to show people around it, so it's nice to have a specimen frame so close at hand. Next time I'll take a photo without pointing the camera at the sun...

This Roseland extension is a little further afield, though still little more than 10 miles in a straight line. Regular architectural collaborator Mark Datson draw up the proposal, but as usual left the specifics of the oak timber frame design to us. It's bedding in nicely, though again I struggled to get many decent images of it. New camera for Christmas? New photographer more like.

Frame Up! And a word on cleaning and glazing...

2011-10-27T09:09:00.001-07:00

Considering the rain we've had since, it's amazing that this green oak frame went up without getting a drop of Cornish rain on it. It's had a good soaking now, but once the roof is on the water marks and associated stains can be cleaned off with a mild oxalic acid solution, which will gently bring the frame back to a fresh, natural finish. I find this is a cheaper, gentler, and less messy technique than sand-blasting.

We'll be back to fit the glazing units and coverstrip, barge boards, fascia and soffit once the builders have finished the roof build up. Direct glazing a green oak frame takes a little while to do properly and ensure a long-lasting weather proof seal, but creates a fine end result that leaves the glass effectively floating on the green oak, held on by kiln-dried oak coverstrip.

A Wood-Build-Bible?

2011-10-27T08:57:00.000-07:00

Building with wood is such an endlessly massive subject, with so many inspiring styles to work from. Books like this are invaluable, whether working on traditionally jointed green oak frames, or more contemporary timber buildings. This books seems to be something of a rarity, an technical resource book with fantastic illustrations and imagery. So much to learn, so little time...

Making Pegs

2011-10-27T08:45:00.001-07:00

We make all the pegs that hold our green oak timber frames together from clean, straight-grained off-cuts. 20mm square billets are split out from suitable blocks using a froe, and then worked on a shave horse with a draw-knife into a tapered 19mm (3/4 inch) peg. This technique ensures maximum strength of the peg, and allows us to make them while still green...by the time they come to be used, they're a little more seasoned and will pull the joinery up really tight when banged into the drawn (or off-set) holes in a mortice and tenon joint. Here's Andy going at full speed for the camera...

Autumnal green oak timber framing and wooden building projects in Cornwall

2011-09-04T14:34:00.001-07:00

First up is this nicely proportioned green oak timber frame extension to a granite cottage renovation near Bodmin, Cornwall. It'll be glazed on all 3 walls including the gable, with a slate roof, and we've worked hard to get the aesthetics spot on to tie in with the existing building beside it. Like the vast majority of our work, the green oak is sourced from Devon and milled by Anton Coaker on Dartmoor...it arrives on Monday - all hands on deck!

The second job for the autumn was due to be rebuilding a waterwheel at a mill near Ladock, sadly this has been postponed til the spring, but the extra time to research and prepare is welcome. Instead I'm building this interesting project that's been in the pipeline for a year now while planning issues have been resolved. It's a departure from the usual green oak construction, and the client has been influenced by a lighter, more contemporary style of timber building, particularly with a nod to the Japanese architect Kazuyo Sejima (below) We'll be using Douglas fir and Larch in conjunction with Stainless Steel wires and brackets in an attempt to create a modern, airy and inspiring work space.

Summer Projects completed

2011-09-04T14:27:00.001-07:00

This big larch barn is still jointed with pegged mortice and tenon joinery but is otherwise very different from the typical green oak buildings we usually make here in Cornwall. The client wanted a large, light and spacious structure, and proposed to stiffen and strengthen our lightweight frame with internal stud-work. I've recently revisited it to hang 4 doors that I made for him, and the end result is really pleasing. You don't often get a chance to frame with hammerbeam trusses, and this was an unusual but worthy application for them.

The late summer project was a more conventional oak conservatory. Designed and drawn by Matt Robinson www.build-art.co.uk, it features these seldom seen down-turned braces, which add a nice detail. A small and straightforward project, and an easier raising than the large larch barn of earlier in the summer. Lets hope it stays dry for Ian and the second fit team to roof and glaze.

A friend was renovating his house up past Truro last winter...he was keen to have a green oak frame to build the kitchen in, but the budget wouldn't allow it. Instead he decided on some bespoke oak stairs which I managed to do at a competitive price, with some nice English oak boards I knew that needed a home. I don't have the workshop set up to make stairs on a regular basis, but every now and then it's fun to divert from working with big green oak beams and do something a little finer and lighter. The photos don't really do them justice, but I was really pleased with how they turned out.

Finished Work revisited

2011-09-04T14:09:00.000-07:00

This client just outside Falmouth has remarkable vision. I'll not guess at his age, but at a time when most are well into their pipe and slippers phase, he's decided to completely overhaul his bungalow. As in, completely. I was sceptical at first, but his experience as a draughtsman and ability to plan and visualise are really coming to fruition. We've now completed 3 separate extensions at his place, and the fourth and final one, a small green oak porch, is scheduled for December.

Old French framing

2011-09-04T13:51:00.000-07:00

My girlfriend has long realised that she is with a timber building geek. She gets dragged round all manner of ancient churches, manor houses and architectural antiquities while I crane my neck skywards and enthuse over roof details. Being French, her native country is awash with all things old and wooden, and our road trips there this summer have been interrupted by heavy braking, reversing and unscheduled stops to take in classic old oak timber framed building.

Deep down, I think she quite enjoys it. Usually we end up in some unspoilt place, looking at remarkable craftsmanship, and washing it down with fine food and drink in warm sunshine. Maybe there's a career in this somewhere?!

Workshop assembly

2011-05-26T13:35:00.000-07:00

Generally we don't fully assemble and erect our green oak timber frames in the workshop, and the first time they're put together is on site, and there they stay! However in a few instances it's handy, to precisely scribe in hips and hip purlins as above, or to calculate and plan glazing installation as below. Tomorrow is raising day for the wall frame below...and it looks like it should stay dry :) Unlike the coming weekend when I'm doing a charity bike ride from Bude to Land's End...130 miles into headwinds and rain :( Typical!

Uncovering patterns of beauty and bewilderment...?!

2011-05-19T11:20:00.000-07:00

Working with green oak on a daily basis is immensely enjoyable...indeed the temptation when talking about the pleasures of timber framing is to slip into a sea of cliches and overused phrases. I'm not going to bother to try to say what's already been said, those who know will already know, and anyway, the pictures do the talking. Suffice to say everyone in the workshop comes to look when patterns like these come to the surface.

How about those medullary rays in this air-dried brace? Not half as pleasing as they are in real life.

Gotta love this time of year

2011-04-26T00:25:00.000-07:00

Its been too long since the last post; too much to do in the workshop, too much to do in the woods over the winter, and too many drawings and quotes to price up for the spring and summer months. Which looks like busy-ness will continue for some time to come...got a really nice variety of oak timber framing projects all over Cornwall, from small quirky extensions and classic roof trusses to large contemporary projects with Douglas Fir, glass and stainless steel. Some are architect led and others I've drawn up myself; some we are simply providing the timber skeleton of the building, and other we're doing the full wall and roof build-up as well. So there won't be as much time as I like to bomb this around the woods!! Happy days.

8 months on...

2010-12-20T02:47:00.000-08:00

The progress on this project hasn't been fast since we left after raising, but it's been deliberate and thoughtful, and the lack of haste and hurry shows in the quality of the build. The exposed frame was infilled with Hemcrete, leaving little trace of the woodwork outside, but exposing the entire structure internally. I'm currently making a staircase and landing to finish off the interior...photos on completion.

Green Oak frame extension with Hipped Roof

2010-12-20T02:31:00.000-08:00

We had to battle the elements erecting this hip roofed extension but apart from the discomfort of working in the rain, it went up really nicely. I like using this dragon tie detail to stiffen the corners of a structure; they give the hips such sure footings as well as adding a really pleasing internal aesthetic.

As always, its nice to see a finished frame clean and bare against a blue autumnal sky, but it's nicer to go back a few months later and see it all finished and looking like home. Again we worked alongside Poore and Sons of Truro on this sensitive extension to a characterful old home, and look forward to going back when they've finished to see the completed project.

A good new old fashionned barn

2010-12-20T02:20:00.000-08:00

A busy few months since the end of summer, and several big projects now raised and finished. The Douglas Fir and Oak barn was raised by hand on a couple of glorious September days...cranes are great for the big heavy jobs, but its simple, safe and efficient to assemble a lighter frame like this using scaffold towers and manpower.

To a slightly fanatical timber framer, few things look finer than the simple detail of a nicely fitted jowl post/tie beam joint against a blue sky.
Think I should get out more...

Tools of the trade

2010-11-01T10:33:00.001-07:00

One of things that initially appealed to me about green oak timber framing was the relatively small number tools needed to build, well anything really. With a framing square and adjustable bevel, a plumb bob, level and string line, a couple of chisels and saws, a drill and some augers, and good leather-faced mallet, you had all the equipment with which the medieval carpenters built the masterpieces of timber construction, many of which still stand today.
Times have changed, and we now have access to all manner of power tools which increase efficiency and reduce sweat, and enable construction carpentry to compete with other styles of building as economically viable. A fair investment is needed to set up even a small workshop like mine, I like the fact that you can still do an awful lot with very little!

A good old fashioned barn

2010-07-31T11:08:00.000-07:00

After a busy spring and summer building green oak timber framed extensions of different shapes and sizes around Cornwall, its quite nice to get back to making a good old fashioned barn/workshop. We started this is in the workshop last weekend, and although its largely built in local Douglas Fir, its nice to be working on a free standing frame that will be raised about 100 yards from the workshop. My back is certainly enjoying the change from hefting green oak beams around the yard!

Roseland Projects Completed

2010-07-31T02:26:00.000-07:00

Recently raised

2010-07-28T10:34:00.000-07:00

This green oak timber frame went up at the end of last week, on one of those days when it poured down everywhere else, but somehow missed Falmouth. The client is updating and re-fitting this house, and wanted a fully glazed extension to make the most of the views out towards Carrick Roads.

The 6m tie beams in these king-post trusses weigh over 250 kgs, with a complete truss weighing over 550 kgs, so we hired this neat little spider crane from fellow framer Stefan Roux. When all folded away, it's no more than 650mm wide, so can be driven on its caterpillar tracks through doors and gate to help raise frames in the most awkward spaces.

Doesn't seem that long ago that we were cutting this in the workshop, laying up the frames in the horizontal, and scribing in each joint with a plumb bob to get a perfect fit regardless of the nature of the timber. All our green oak frames are laid up like this...its the only way of ensuring really good tight joinery and the massive structural integrity that goes with it, as well as making raising the frame a simple, fool-proof process.

Right on track?...

2010-07-28T10:03:00.000-07:00

I took a break from green oak timber framing in May to help a friend work on his railway carriage. This old girl is about 130 years old apparently and made the long journey down from Suffolk earlier this spring...I think it used to operate on the Great Eastern Line. The story is that after the war, returning soldiers were often housed in decommissioned railway carriages, and over time these were extended to and became the core of a rambling, sprawling self improved home. There are about 9 layers of wallpaper inside this to suggest this was indeed the case.

Like so many things of the Victorian age, it was extremely well built; an oak carcass on a massive steel subframe, and then externally clad in teak sheets and trim. The bogeys and wheel sets are long gone, and the past 100+ years have taken their toll. However, the new owner is keen to preserve what's left and replace what's too far gone, so we spent some time cutting out and replacing rotten window sills, door frames, re-glazing throughout, and insulating and re-roofing. With a new set of doors, a woodburner, and many more months of tlc, there'll be life in the old girl yet.

October Extension Revisited

2010-05-16T08:06:00.000-07:00

After finishing the last frame on the Roseland, we went up the road a mile to where we raised these hipped roof trusses in late autumn last year. Credit to the Project Manager for his attention to details, and to the builders for making a fine job of the second fit work.

Its always so nice to revisit previous work and see it transformed from bare frame on a building site to a warmly atmospheric living space. Combine this with a freshly baked cake and good pot of coffee, and it capped a good week for us.

Roseland Garden Room

2010-05-16T07:54:00.001-07:00

We've just raised this garden room frame, another project through architect Mark Datson, and working alongside Steve at C Poore & Sons builders. We've done enough jobs as a team now that we know all about each others processes and requirements, and can execute projects quickly and efficiently. Despite difficult access and indifferent weather, 2 of us raised this in a couple of days, after less than 3 weeks of cutting in the workshop.

Guedelon

2010-05-16T06:33:00.001-07:00

A couple of weekends ago I went to see the Chantier Medeieval at Guedelon in Burgundy, where a 13th century chateau is being built using the materials, tools and techniques of the age. Work began in 1997, and they aim to be nearing completion around 2025, though in a way this is a project without end. Far from being an exercise in romantic Luddism, it's a remarkable insight into the ingenuity of master craftsmen in an age long before power tools, CAD and the hydraulic ram.

The ever increasing number of visitors to the site have allowed the project to become self-funding, and since all the materials are quarried, felled or dug from the site, the only real costs are labour. The infrastructure around the site is as authentic as the chateau itself, with the surrounding forest being dotted with the workshops, forges, sawpits and kilns of the tradesmen. A building site like no other, and well worth a visit. See www.guedelon.fr for more details.

Grappling with CAD

2010-03-08T14:19:00.000-08:00

I've always enjoyed doing pen and ink framing drawings but they are time consuming and limiting compared to the capabilities of modern CAD programs. Finally I've taken the time to get to grips with a simple but effective package, and am already finding how much easier it makes so many aspects of the pre-workshop stages. Customers get a clearer impression of what they're getting, builders and architects can visualise and discuss techincal details, and I save hours of time producing my drawings. Not such a luddite after all!

Cottage Extension and Link

2010-03-08T12:33:00.000-08:00

We've just raised this Douglas Fir and Oak frame in perfect March sunshine. We cut it in the workshop over Christmas and New Year, but the builder was held up by the wintry weather in early Feb and so it sat in the corner for a while, waiting for a sunny break. It went up in a day and a half over the weekend and was definitely worth waiting for the weather window.

The oak curves tie in really nicely with the Douglas Fir frame, and although not as nice to work, the Douglas is a great cheaper alternative to using green oak, with excellent strength, longevity and local availabilty. It'll be externally clad in 400mm of Hemcrete, and roofed in slate, while the linkway will be weatherboarded with large glazed panels.

Building bridges

2009-12-23T11:49:00.000-08:00

I've just finished putting this little bridge up in the woods at Crenver Grove near Praze-an-Beeble. A really enjoyable project to do, and my first venture into bridge building; admittedly not too demanding but lovely working in the woods for a few days. The woods are managed by the Sustainable Trust and are open to all...there are events there throughout the year so there'll be plenty of traffic over this muddy ditch through the years.

Green Oak Extension

2009-11-25T02:02:00.000-08:00

The 2nd of my green oak frames on the Roseland has recently been raised, much dodging of downpours and gales, but otherwise a quick and straightforward assembly. Nice deflection in these curved tie beams, and the dragon ties in the corners provide interesting detail where the hips drop in. Unfortunately another looming downpour meant that the tarps and covers went on this before I could get some better photos, but I'll be back in the spring for a visit when all is finished...

Garden Bench

2009-10-25T12:37:00.000-07:00

In the little gaps between large scale oak framing work, there's still smaller projects coming out of the workshop in Falmouth, Cornwall. I had long wanted to make a garden bench along these designs, from large clean slabs of green oak with wedged through tenons. When an old family friend recently married, I had my opportunity... Best wishes Jon and Viki.

Living Room Linkway

2009-10-14T12:12:00.000-07:00

The first of my 2 oak framing projects on the Roseland, Cornwall over the autumn, this linkway between old cottage and new extension features wedged dove-tailed through tenons in the collars for added strength. Difficult to raise by hand but it still all went together nicely in 2 days. As always, I look forward to going back when its all finished and getting better photos.

Like it's been there forever...

2009-09-28T14:42:00.000-07:00

This conservatory was another collaborative effort between Jamie, Joel and myself...there's a picture of it being raised in Gallery 3, but it's nice to see it 4 years down the line, looking very well settled and part of the landscape. Its curved tie beams inspired the design of the trusses in the extension I'm just about to start on.

Rosy on the Roseland

2009-09-02T11:31:00.000-07:00

My next 2 projects come from the drawing board of an architect on the Roseland Peninsula. Jamie Lovekin and I built this balcony and staircase for him 3 years ago, and we're now going back to build a kitchen extension for him. He has also drawn up another oak frame for us, a crisply contemporary linkway dressed in glass and slate. Due to start both next week, workshop photos coming soon.

Furniture too..

2009-09-02T06:59:00.001-07:00

In between the larger construction carpentry projects, I'm always glad to take on furniture and garden commissions. Most are of Cornish Hardwoods, with a pegged and wedged assembly that reflects the joinery techniques in the larger scale building work. Generally I like to finish them with a clean, light oil, giving durability while allowing the character of the wood to remain accessible to sight and touch.

Oak coffee table with chestnut slats reclaimed from split roofing lathe (2004)

Solid Beech dresser (2006)

Oak bench outside Liskeard hospital. Colin Milburn takes the credit for this one; I helped him make and install it. His design reflects the St Piran's cross, and the oak came from his farm below Bodmin Moor; we stained the uprights black by allowing the tannins in the wood to react with iron filings in a large bath. (2003)

I made the above bed for my sister in 2004 using ash and spaulted beech from Tino Rawnsley's timber yard near Wadebridge. Its assembly involves just 4 wedges, for ease of carrying up narrow stairways. The bed below is again of ash, with nice olived features in the head and foot boards, this time assembled using pegs.

This garden bench was made using leftovers from a large oak frame we built in Hampshire, and using framing style joinery...all pegs and wedges, not a nail, screw or drop of glue in sight (2005).

Oak and Beech Table and Benches (2005)

Solid Oak doors; framed, ledged and braced (2007).

Hand-split Sweet Chestnut garden gate, pegged mortise and tenon joinery (2007).

Oak and Chestnut seat around old apple tree. (2006)

Workshop Raising

2009-08-23T08:29:00.000-07:00

The workshop in the woods went up on June 9th 2007, culmination of 10 days of cutting and joinery, weeks of weather watching, months of letter writing and form filling, and years of dreaming and planning. A fine crew turned up on a fine day, and after 3 hours of leveling, lifting, placing, raising, hammering and pegging....the Douglas Fir frame was up and sitting pretty in its new woodland home. The fire was lit as the sun dipped, the fish fried and the venison stewed, the ale supped and the guitars strummed. One of those memorable days, the fulfillment of a long held dream, a wee hut in the woods. Thanks to all who helped, the kettle's always on....

When September comes...

2009-08-23T08:11:00.000-07:00

Middle car park, last September....the light in the autumnal tunnel. Got a lovely series of framing projects lined up to start in mid-September, which leaves a couple of weeks to tidy the workshop, sharpen the tools, get in the water and on the coping.

Gulval Barns

2009-08-23T05:27:00.001-07:00

I've just finished a 7 week project in Gulval near Penzance, a 4 bay barn renovation with some interesting features. Stefan Roux designed and drew the frame, Anton Coaker supplied the oak, and I worked with the customer on this one, leading him and a young lad through the framing and raising. Jamie Lovekin and I had worked with him before, building the roof for another barn at his place, the one he now lives in (below). Always nice to get repeat work and see how past projects are settling in, and I look forward to seeing the new project when finished.

Gallery1

2009-08-16T11:51:00.000-07:00

(above) Shelter Seat in Coronation Park, built in conjunction with Tino Rawnsley, 2007. Oak frame, copper sheet roof.

(above) Barn renovations near St Issey, working with Jamie Lovekin, 2006.

(above) Douglas Fir Bus shelter and bike shed outside the hospital in Launceston. Colin Milburn's project, 2003. Western Red Cedar shingles and cladding from Tino Rawnsley.

(above and below) Joel Hendry designed and lead this project, the biggest one I've worked on. Adding to the remains of a Dartmoor longhouse, we built this 8 bay frame in the summer of 2006, using barn space in the farm next door, with Devon oak from Anton Coaker. A great job to work on.

Gallery 2

2009-08-16T11:42:00.000-07:00

Poolhouse in Kent, 2005, green oak frame and cladding, with tiled roof. Built alongside Simon Scott, in Hever.

Angled linkway between barns, again at St Issey with Jamie Lovekin, 2006.

Forestry Barn at the Royal Cornwall Showground. The first green oak frame that I worked on, 2003, it has an interesting range of infill styles, including cedar cladding, lime render, woven split oak and wattle and daub. Great to see it come to life every summer during the show.

Pottery workshop in St. Kew, another project with Jamie Lovekin in 2005/6. The potter has a fineworkshop, I have a fine teapot and mugs.

Gallery3

2009-08-16T11:31:00.000-07:00

(above and below) Extension to a listed thatched cottage in Hampshire, again built working alongside Jamie Lovekin, 2005. We built this frame in the workshop at Gear Farm, nr Helford, then shipped it up to the site and assembled it in 2 frosty winter days.

(below) Conservatory Roof, extension to old mill near St. Germans. Collaboration between Jamie, Joel Hendry and myself. Oak frame with Douglas Fir rafters. 2005.

(above and below) A pair of porches at the Old Carpentry Shop, Trelights, 2006. A small enough job to do on my own, though helped with raising by a good builder.

As well as making the porches, I made a pair of oak doors to fit under the front porch, and a seat to go around an old apple tree in the garden. A very enjoyable series of commissions.

(above and below) This barn renovation at a Duchy owned farm near Cullompton, was the job where I really learnt the core skills of oak framing. Working under the instruction and supervision of James Lovekin, a team of 3 built this frame in 6 weeks in 2003. With interupted tie beam cross frames, and plenty of vernacular authenticity, it really fired my excitement for this fine style of woodworking.