How to Create a Post and Beam Archway

This next HouseCalls request took Ron to Olympia, Washington. The Podowicz family had done a few updates and a remodel to their home, but they still felt like there was something missing. Cathy wanted to add some type of architectural detail that might create a lodge atmosphere in the home. Ron recommended that they capture this effect by adding a rustic post and beam archway to the opening of the dining room. The result was so inviting they may never get their future houseguests to check out!

Click Here For a list of what you will need in order to complete this project.

Click here for a complete video of the project.

To create the rustic look that Cathy and Tim wanted, Ron designed three elements: a beam, two posts and two diagonal braces often called knee braces. These were designed to look authentic but, actually Ron's design involved a bit of trickery.

Using what is called box construction, Ron created these posts and beams out of several pieces of wood put together to look like solid wood. In reality, the structure Ron designed was hollow on the inside.

1. Cut wood:

• The first step was to fashion the individual pieces of wood to create the beam, post and braces. They began by cutting standard 1 x 4s and 1 x 6s into strips of varying widths.

• Next, they made angled cuts or bevels along the edges. To do this, they set the blade on a table saw at a 45-degree angle.

• With the bevels cut on the edges, it was time to measure and mark for length and then make these cuts with the miter saw.

2. Assemble beam:

• After they had cut all the wood for the entire project, they began to assemble the pieces. They started with the beam that ran along the ceiling. Ron created a little mock up to show them what it would look like.

• Yellow wood glue was first applied to the bevel cut edges. Then the sections were placed together and carefully aligned.

• Small-headed finish nails were driven in with a pneumatic nail gun to hold the pieces together until the glue dried.

3. Assemble posts:

• With the beam finished, they moved on to the posts that would appear to support each end of the beam. The process used was the same but the shape was slightly different. The posts were designed more like a shallow "U".

4. Assemble knee braces:

• Finally, they assembled the knee braces. After the these were glued and nailed together, they resemble long hollow boxes. On each end they made 45-degree cuts (or miters) that would allow the braces to fit snugly between the beam and posts.

5. Archway assembly:

• To assemble the elements together, they began by screwing a strip of 1 x 4 lumber to the ceiling to act as a cleat.

• They slipped a section of the ceiling beam over this cleat and nailed it in place.

• Next, they measured the remaining distance to the wall, cut the next section to length and slipped it into place.

• To cover the joint between the sections, they created a make believe scab. This was designed to look like a brace used to join real beams together.

• An authentic scab would have wooden pegs that pass entirely through the beam. Ron's pegs were only long enough to enhance the illusion.