by Jacob Mooney
James set out to discover where traditional woodworking skills are still essential in today’s industries. High-end furniture construction was one area, as well as the restoration work on the old oak framed buildings around the United Kingdom. However, the area that really caught James’ attention was the resurgence of interest for post-and-beam timber frame buildings.
James decided that building a timber frame would be a great way to illustrate the usefulness of their woodworking skills to the students. With the involvement of local timber companies who donated the timber, James ran an extra-curricular course, and they built a timber-frame structure together with the kids. “I was trying to encourage the kids themselves to look at other avenues of employment,” James says. “That was the whole point of it all.” However, when the building was finished, several of the sponsoring timber companies told him that there was really a market in the area for such construction, and that he should make a go at it.
Encouraged at the prospect of being his own boss while working with a material he loved, James attended timber frame courses in England and the United States. In the US, he attended courses of the well-known Steve Chappell of Fox Maple School of traditional building. “The system in America seems to have developed from all the different nationalities that have settled there,” James shares. “Which is quite good, because they have taken the best from each.” With this diversity of training, James has the ability to choose from a variety of traditional techniques and joints from around the world, depending on the project requirements.
In 2007, he went full time with Thomson Timber after building some trial buildings, which quickly sold. He found that his varied experiences with mechanical engineering, desktop publishing and marketing contributed significantly to their success. His proficiency with AutoCAD made designing buildings and standardizing the traditional techniques and joinery easier and more efficient.
Thomson Timber is located just east of Glenrothes, Scotland where the location is rural, but within a short drive of the coast and Edinburgh. They attend local fairs and shows, and generate a great deal of inquiries from their timber frame stand. The common denominator among their clients is that they own land, horses, or both. “If you look at what is on the market today, they [ready-made buildings] seem too flimsy,” James says. “People don’t like that flimsiness. They would rather spend the extra and have something that is going to last a lifetime.”
James initially sits with the client and sketches out a three-dimensional drawing of the house extension, barn, gazebo, or whatever else the client might be dreaming of. James then makes an official proposal and drawing in AutoCAD, which generates an accurate materials list and final quote for the project. When a price is agreed on, James often will then make a scale model of the project and review it one more time with the client. “In my experience, having that hands-on approach is vital where they can take the model and move it around in space,” relates James. “They can decide to move a door, add a different kind of window, or change the orientation slightly.” Building the model helps him think through how he wants to accomplish some of the more technical joints and carpentry on the final project.
Once the project plan is finalized, the real work begins! Logs are often selected before they are felled, so that the right lengths and cuts are made. Once the logs are delivered, further selection takes place as they pick and choose the right logs for each component. Then the logs are loaded onto their Wood-Mizer LT15 sawmill to be turned into beams or posts. Posts, for example, must be cut from the very center of the tree – boxed heart, so that when they shrink in the future, they will shrink equally on all four sides. “That’s one of the main reasons we have our own sawmill,” James explains. “We couldn’t get commercial sawmills to supply us with specific cuts from a tree. In timber framing, it’s very important. We need to know we can use certain cuts of the tree for certain areas, knowing in which ways timbers will shrink and distort.”
Beams and posts are milled slightly oversized, because James’ sawmill includes an additional attachment for final planing and moulding. “The advantage of having the Wood-Mizer MP moulder on the same rails as the sawmill means we never have to take that timber off the machine,” James shares. “We can plane it to exactly what we want. It gives us a nice surface finish for interior timbers, and gives us an accurate and planed beam that we can easily work out reference faces for the traditional carpentry.” Once the beam or post is square and smooth, a rod is used to precisely mark out the locations of the joints. These are then cut with a chain mortiser and traditional chisels.
A trial assembly of the building is generally made at Thomson Timber, whether partially or the whole project. For projects that are impractical to fully assemble, they have practice mortise and tenon joints on hand to make sure everything fits as it should. Because of requests from customers for a building that could be dismantled easily, James has adopted and prefers a mechanical linking system to connect his joints over the traditional mortise and tenon method.
“I came across a dozen or so different methods,” recalls James, “But in my opinion, the simplest and most efficient way of joining the timbers is to use the TimberLinx system. The whole building can be assembled virtually with only an Alan key. We can take buildings up and down in a couple of hours, without special equipment or special skills.” One of James’ goals is to leverage this system in a way that he can sell smaller buildings as a DIY kit, which certainly sounds promising as an area of business growth.
They enclose the building using insulated panels backed with plywood. The inside can be pre-painted or stained depending on the final look required by the client. The panels can be used as the roof insulation as well, allowing them to make the building wind and watertight in the same day. Between the larger projects, furniture and fireplace mantles keep them busy. They sell mantles all over Britain, and use a 4 foot wide belt sander to produce mantles and tabletops.
“From my point of view,” James shares, “Being able to produce items that will outlive me, and making use of the craftsmanship that’s required to achieve that, that’s probably the main attraction of my business. One of the things we find is that our customers spend a lot of time sitting in the building, just looking at the building, rather than looking out the windows! That’s a great compliment.”
Watch the video here: https://youtu.be/sud6VXcXMJI
Categories: Success Stories, Custom Sawing
Tags: LT15, Sawmill