my new flat roof joists are going to sit on the purlin, but it seems wrong to have them sitting on the point at the top, so should I make pieces of wood to sit in between and spread the load, how to do this so that they'll last a hundred years and not split?
Seems to work OK for me, although it does ask for a log-in, which I ignored.
I'll admit to being totally ignorant on structural matters where roofs are concerned, but why rely only on the purlin for carrying the flat roof. Why not put a couple of decent sized bolts (with washers) through the flat-roof joists and the adjacent pitched roof rafter where they overlap, some wood glue (Cascamite or Gripfill) in between, and tighten up?
I was going to say that - well, screw then to the rafters, with a couple of corrosion resistant 6mm screws (self drill and/or pilot holes as required).
I would not just sit them on the purlin - you are loading it the reverse way to what it was designed to do - and your new rafters will try to pull it off the old rafters.
In fact I would consider running a new beam on the top of the old rafters to the load is going the *right* way.
Since we are talking about a flat roof, its presumably not carrying much load anyway?
I would simply fix them to the adjacent rafters (probably with a bolt through, and a timber "dog" between the timbers).
If the purlin is not level. then use different heights on the rafters to get your new joists level. You can use firrings of like slope, but increasing thickness to get your compound slope.
Putting a downwards load on them is going to try to pull them off.
Normally, the purlin is in compression against the rafters (to support their mid span) - you proposal reverses this and I think that's dubuious
- unless you add some plates or other means to tie the purlin to the old rafters under tension.
Wherever height you want the support for the new rafters (which I assume is the same height as you were going to use the purlin as support, weren't you?
Right...
So where's the downward load going to go, when you hang the end of your new roof off the purlin?
If the wall plate and/or old rafter ends are knackered, is the purlin well and independently supported to accept a vertical load (normally purlins take load at 90 degrees to the rafters and usually have thrust poles running back to the centre wall)?
I think we need some pictures from inside the roof of the old rafter ends and wallplate and the purlin support poles.
I prefer thin self drilling screws - minimum disruption to the wood (like nails) but more subtle. Spax do a nice one, that I've been using for a not totally dissimilar job:
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Available from Amazon.de (seems to be no problem shipping to the UK and took 2 days for me).
But it's not somethign to argue about - nails have served people for centuries in this role. In my case, I did not want a lot of banging disrupting the good bits of the roof.
I wouldn't underestimate snow load - I did the calcs on mine and dry, the roof weighs an estimated 1000kg (adding the per m2 mass of the roofing components). Adding worst case snow load to SE England standards that I found somewhere on the web took the total potential mass to 2400kg.
That's what I would have considered as an option, but the OP did say something about the old rafter ends and/or wallplate being dodgey - I think we need to know more :)
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