Wood beams can add accent to a room
A box beam can be used for decorating when you don't need a solid beam for support. They are lighter, easier to install and less expensive than a solid beam of comparable size. Best of all, they can be cut and assembled in a relatively short period of time. By using veneered plywood, you can fabricate a beam with a variety of wood finishes that might be otherwise difficult to find. A few tools, plywood and a basic knowledge of woodworking are all you need to get started.
Instructions
1. Set the rip fence on saw for a 6-inch cut.
2. Rip two 6-inch by 8-foot strips from a sheet of plywood with your table saw.
3. Set the rip fence on your table saw for a 5-inch cut.
4. Rip six, 5-inch by 8-foot strips from the remaining plywood.
5. Remove the rip fence from the table saw.
6. Cut four of the 5-inch strips into 5-inch squares. Use the miter gauge on your table saw to get a square cut. Use measuring tape and a pencil to mark one 5-inch cut at a time. These will be used as internal supports for the beam, so it is imperative that they are cut to a uniform square, 5-inch by 5-inch size.
7. Place one 5-inch by 8-foot strip flat on the floor. Run a bead of wood glue along both long edges of the strip.
8. Place the two 6-inch strips, on edge, along either side of the 5-inch strip.
9. Align the ends of all three strips and use a bar clamp on each end to hold the boards in position.
10. Use the hammer to drive a finish nail about every four inches along both glued edges.
11. Measure and mark the inside of the beam at 4-inch intervals.
12. Place a 5-inch square support inside the beam at each mark. The supports should be placed vertically so their edges will make contact with all sides of the beam.
13. Nail the internal supports in position through the side strips with finish nails.
14. Apply a bead of wood glue to the long edges of the remaining 5-inch strip.
15. Slide the strip into the slot remaining on the top of the beam. If all your measurements are correct, it will rest on top of the internal supports and its top will be flush with the edges of the beam's sides.
16. Nail the top strip into position by driving finish nails into the edges of the top through the side strips.
17.Use a nail set to set the heads of the finish nails 1/16 of an inch below the surface of the boards.
18. Apply wood putty to the nail holes and allow it to dry.
19. Sand the putty smooth over the nail holes and you are ready to finish the beam.
Tags: your table, finish nails, internal supports, 5-inch 5-inch, 5-inch 8-foot, 5-inch strip, 8-foot strips