Replies

1. 
   reinvent | Nov 06, 2004 08:12pm | #1

   If it has to be an ellipse and you decide to do it yourself then invest in a long narrow vacume bag set up. You will never get all the glue joints tight otherwise. Screw blocking to the floor in the shape of the inside of the elipse and clamp the whole thing,(lami glue, and vac bag) to it. Get a lot of helpers and a whole lot of clamps. I would recomend speed claps like Bessy makes. C clamps are a pita for this sort of job.

   Your lammis are probbably gona hafta be pretty thin, 1/8" or so to make the bend. Straight grained mahogany would be best but spanish ceader would be a good 2nd choice. I would also recomend West System for the epoxy (used in boat building all the time).

   Do a dry run(no glue) with the vac bag and clamps to make sure you didnt miss anything.

   Take some pics so we can see.

   Good luck.

1. 
   Sphere | Nov 06, 2004 08:22pm | #2

   As an aside...remove the'tommy bar' on a C clamp and weld a nut to the screw shaft, you can then speed screw them with a drill and a socket. Then really torque them with a ratchet or wrench. 

   Spheramid Enterprises Architectural Woodworks

   Repairs, Remodeling, Restorations. 

2. 
   TrimButcher | Nov 06, 2004 08:25pm | #3

   You would have to use a glue like resorcinol...not many glues are rated for structural exterior.

   Yes, you are being VERY masochistic if you are thinking of laminating your own beams.

   Regards,

   Tim Ruttan

3. 
   davidmeiland | Nov 06, 2004 08:28pm | #4

   I can imagine that someone, somewhere, could make that for you, but it's gonna be a long search.

   I like the idea of the vacuum bag, but you didn't mention the depth of the ellipse. The vacuum bag idea would work well if you were trying to laminate veneers vertically into a curved LVL, but if you go the other way and use 1x or 2x thickness oriented horizontally, you could do more of a glue-and-screw approach... cut lengths of 1x12 or 2x12 into the ellipse shape, and stack them one at a time.

   Depending on length you would probably need to butt-join at least two pieces per layer, stagger the joints, etc. Lots of cutting, but it could be done by a guy with either a 5-gallon bucket full of jigsaw blades or two guys with a huge bandsaw. Oh, and then you'd need a mile or two of belt sander belts to sand the faces of the sandwich into presentability.

   I say go for it. If you find a shop to order it from they'll just do it the same way you would, using less-skilled and less-concerned guys than yourself.

1. 
   TrimButcher | Nov 06, 2004 09:23pm | #5

   David, I disagree. Custom-manufactured curved glulams exist and can be made by a capable glulam manufacturer. Attempting a DIY glue-up of a structural exterior beam screams "liability issue" and "more time & effort than it's worth".

   Ger, look at http://www.apawood.org for glulam manufacturers.

   See this article for unique applications (eg. curved exterior) of glulams.

   Regards,

   Tim Ruttan

1. 
   davidmeiland | Nov 06, 2004 10:16pm | #7

   I think it entirely depends on how it's approached. I personally wouldn't attempt a 26 foot long LVL-type beam made of 1/8" veneers in a vacuum bag. That's something better done by folks who do it all day and have the veneer and tools right there. A glu-lam type stack is a lot more friendly. Depends a lot on the 'radius' he needs. If it's gentle it's a lot easier. I've seen plenty of built-up stuff done on jobsites, as I'm sure you have too.

   I've ordered curved glass, metal, and wood, and it takes a lot of time and discussion to get that done too. Just getting an appropriate template for an ellipse out to a manufacturer would be a challenge. If it can be described mathematically, it gets a lot easier, but I still say he should at least look at a comparison of his own time and cost vs. buying it out. Also, he's saying gazebo and not structural header--I would not make the latter myself if I could buy it with a stamp on it.

4. 
   USAnigel | Nov 06, 2004 10:03pm | #6

   Check out some local churches for the type of beam you need. Then find the contractor who built it and then who made the curved stuff you need.