Hello - I have a new project to build a small front porch/stoop roof. No big deal except this one will have a barrel vault ceiling. Essentially it will look similar to this one
The one in the picture has a bead board ceiling following the 2x4 rafters and a curved plywood front. My customer wants a true barrel ceiling. I have the plans for the design in my picture and everything is straight forward but since the plans are for the ceiling following the rafters, not the curve, I have a question or two.
First - The rafters - I figure I will use 2x material with plywood cut to the appropriate radius to attach my, probably shop made, t&g boards to. Construction adhesive and brads or finishing nails here. I'm not too keen on nailing into the edge of ply. Any thoughts on this?
Second - THE MAIN QUESTION. How would you handle the details of the connection between the plywood facade's radius curve and the ends of the beadboard? Would you lap the bead board ends under the plywood and have the end grain exposed to the front? Would you butt the ends of the beadboard to the plywood and have the plywood edge exposed below? I think I am leaning toward the second. If I go that route would you do anything to finish the plywood edge or just paint it as was done in the picture above?
Third - And a just curious question. How long would it take you to build what is shown in the picture with the modifications I described above? Support would be via brackets, not posts. Siding will need to be cut back, j channel installed, roof applied and a light hung (Including new wire from existing switch). Customer will paint, I will caulk, fill, sand and back prime. Moldings are stock. Would you completely site build it or would you build it in your shop and do final install on site? I'm thinking of building the gable and brackets in the shop, install the brackets and get someone to help me lift the whole thing onto the brackets then trim it out, wire it and roof it. Barring that, I may build the trusses and brackets ahead of time and then put it all together on site.