I guess this would be considered woodworking, on a big scale... I'm looking to taper and radius the ends of a number of 8x8 and 8x10 douglas fir timbers. These will be used in a hybrid-frame house project. Basically, I intend to cut a gentle radius starting about two feet from the end transitioning into a tighter radius right at the end. Since I have several dozen beams to treat, I'm trying to figure out the most efficient method. I've seen a method using a circular saw to cut a series of kerfs with depths that follow the desired profile. The waste is knocked away with a chisel and final cleanup is done using a belt sander. This would work, but it seems slow because of having to reset the saw depth dozens of times for each beam. The volume of dust and chips this method would create is also undesirable. My current thinking is to build a profile template that indexes to the side of the beam. I could then use a 1/2-in dia, 2-in deep spiral cut bit in my 2hp router. Working from opposite sides, would produce matching two-inch-deep cuts in the beam following the desired profile. This would still leave almost 6-in (9 1/2 in - 4in) of the cut yet to be made, but the grooves could be used as rough guides. I think I could make these last cuts with a large bow saw or possibly a long blade in a reciprocating saw. Either way, I'd end up doing clean up with a power planer and belt sander. At least this method would slab off the bulk of the waste in one big chunk cutting down on the dust. The largest beams I'll be working are close to 400 lbs, so running them thru any type of stationary tool is out of the question. Additionally, I'll be working with one beam at a time on saw horses, so I can't do all the ends at once. Anyone have a better idea for working the ends of these big sticks?
Richard Johnson Camano Island, WA