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Transcript:

Well I'm off to visit Mike Kerrigan and Lisa Holen now they live just up the road in Gloucester, Massachusetts. They're very proud of their town's history and they want their home to reflect that traditional New England style.

That's why they have enclosed their deck with a classic lattice fence featuring an archway. But two year old daughter Kashlin is pushing farther and farther in her childhood explorations. So now Mike and Lisa need a gate under the archway and I've come to help them build it.

This is very nice. So is the gate just for appearance sake or is there a security issue here with Kashlin.

Security, yeah and looks too.

A little bit of both?

A little bit of both, OK.

What I'm thinking is something pretty simple, but kind of an arched top that sort of mirrors the arch up here and the top of the entryway here and then a latticework that picks up the latticework that's already there. So how does it look to you guys?

Looks great.

Looks great.

OK.

After laying down Kashlin for a nap, Mike and Lisa join me on their driveway where I've laid out the lumber for their gate.

Ah this big piece right here is going to be the top. It's out of this that we're going to cut this arched shape right here, ah the sides here and here I've laid out over here and the bottom, this piece of four by four right here. Now all this is guys, is a couple of pieces of this two by twelve right here that I glued up with some waterproof glue and then clamped it. To create the side pieces we'll glue not just two, but three boards together to form a sandwich.

And then if you can take the brush here and just kind of spread this out, this is sort of stiff.

Should I cover it all the way, or?

Yeah, that's good, as much of an even coating as you can get with that. That's good.

This is polyester glue we're using today. It cures or dries by reacting to moisture. So I brush water on the face of the bottom board to promote a better bond when we join the two surfaces together. Lisa aligns the end of the middle board with a line I drew on the bottom board, then repeats the process with the top section.

I will say one thing about this glue. I've ruined more than one set of clothing with this stuff. It is very, very strong, it will never let go of the wood and will never let go of your clothing either.

When assembled, the shorter center board and the two longer outside ones form notches at each end called mortices. Our next step will be to cut “tungs” or “tenons” in the ends of the top and bottom rails that will fit snugly into the mortises creating very strong joints.

And to do that, we're going to be cutting away every place here that I've got an X and we're going to use the power miter box to do that. You will notice what I've done is I've set the saw so it only comes part of the way down and we'll place the wood in here, line the blade up with that first line right here and then we're going to make a series of repetitive passes back and forth and each time, we'll pull this out a little bit until we've removed all of that wood. and what we'll have left is the tenon.

Shaving the board, one saw blades width at a time, Mike and Lisa create the first half of the tenon, then they flip the board over and finish the job.

Very nice guys!

After cutting a second tenon on the opposite end of the bottom rail, we repeat the process for the top rail.

Alright guys, there we go, there's our tenon.

On a wide plank like this, it's not unusual for the saw blade to leave a small ridge on one end, so I cut it away using a chisel.

So let's slip these together.

It just slides right together.

Should go right, the tenon should go right into the mortises, there like that.

It looks OK.

You guys did a great job. So have you had a lot of gate building experience before?

Well, we've put up a couple of baby gates in the house.

And I probably could have used your help doing that.!

Oh, yeah?

Haha

Oh oh.

Next we'll cut the top rail to form an arch.

Now that's going to be cut out of this wide piece right here and I made up a template out of a piece of scrap plywood. So what we'll do is lay this on here, like this and with the pencil we just draw this arch right around here. Like that.

Nice.

The top curved rail will be three inches wide, so we need to draw a second parallel line that distance from the first. No, we can't just use the same template because this second line has a slightly larger radius. So we set a compass to three inches and plot a series of points beneath the first line.

When was the last time you used a compass?

Oh, I don't know if I ever use one.

Third grade?

Haha

Mike taps in small nails on Lisa's marks and now it's time for the old bent stick trick.

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