Beams add architectural detail to a home. They can be used to emphasize a ceiling, as a post to support a horizontal beam and as headers for doors and cased openings. In some cases, a real beam would be cost-prohibitive or the building's structure may not be able to support the load. This is where a simulated wood beam, also know as a box beam, can replace the real thing. The do-it-yourself handyman can make custom box beams with a few woodworking tools.
Instructions
1. Glue the boards of box beam wood as needed to make the size beam you need. An 8-by-12-inch box beam requires two sets of boards 12 inches wide, and one board 8 inches wide. This is for a three-sided box beam. Measure the wood with a tape measure.
2. Run the boards through a jointer to get a perfectly square and flat surface for the boards to be glued together. Apply a layer of wood glue to one of the jointed edges and clamp the two boards together. Be sure that the two boards are aligned as you apply pressure with the clamps. Repeat this step for all three sides of the box beam. Let the glue dry.
3. Place a 45-degree locked miter joint router bit into the router table. Adjust the router bit for the thickness of the material you are using. Test the fit by running some scrap pieces of wood through the router table. Adjust as needed.
4. Set up a featherboard to support a board that runs vertically through the router table. This is for the center board of the box beam. Start the router and run both sides of the 8-inch board through the router table. Run the board with the good side facing away from the router bit.
5. Measure the inside of the 8-inch board between the two routed edges. Cut some pieces of scrap wood the width you just measured to be used as spacers as you glue up the box beam. Use a table saw.
6. Move the featherboards to support the boards as they are run horizontally through the router table. Run one side of the 12-inch-wide beams through the router table.
7. Place both of the 12-inch-wide boards on a work surface. The outside face should be facing the work surface. Apply wood glue to the joint and evenly spread it over the entire joint.
8. Assemble the box beam by placing the 8-inch-wide board into one of the joints that you just glued. Take the second 12-inch board and set it into the routed joint of the 8-inch board. Align the ends of all three boards. Place the spacers in the open end of the box beam to support that side of the box beam.
9. Place a piece of wood 3/4 inch thick by 2 inches wide the same length as the box beam as a clamping block. The clamping blocks help apply even pressure along the glue joint. Place it on the narrow side along the edge of the box beam over the glue joints. Apply woodworking clamps to the box beam along the glued edge. Tighten the clamps until the joint is pulled together tightly and wood glue starts to squeeze out. Let the box beam dry.
10. Remove the wood clamps and scrape off any glue residue. Use a scraper to remove the excess glue. Sand the box beam.
Tags: router table, through router, through router table, 8-inch board, inches wide, wood glue, board into