1. Selection of timbers
Wherever possible we use mills whose logs are sourced from Devon & Cornwall and are then machined in the same locality. Each timber is cut from the round, the “green” (un-seasoned) timbers are cut to size – sections usually up to 400mm and 8.5 metres in length. Freshly cut douglas fir exhibits a mixture of cream and warm pinkish-red hues

Timbers are normally cut as close to size as possible but there will be some movement of the wood as the timber gradually dries out. This movement is perfectly natural and helps give the prodect a traditional, hand-made feel

2. Trusses and framing
All the framing was performed offsite, mortice & tenon joints were cut and assembled by our sister company, Harris Timber Offices, at Whimple near Exeter. The finished framework was then brought down to our new site at Ipplepen and re-assembled.

All timbers were left untreated because we wanted to maintain the original colour of the douglas fir. Where required we can get untreated timbers processed with Pro-Tim clear preservative up to and including Hazard Class 3.

3. The building takes shape
Large sawn douglas fir timbers give the frame a very solid feeling. Sole plates of 150mm x 150mm were bolted to the concrete pad and the solid feeling of the building was enhanced with ring beams and joists also using 150mm square timbers. Purlins of 150mm x 75mm help support the douglas fir joists.

Traditional style timber frame buildings using green oak, douglas fir and larch have become increasingly popular. We used douglas fir mainly for appearance and heartwood was used for most of the frame to minimise movement in the truss and braces.

4. Roof construction and making weatherproof

5. External cladding and waterproofing
The completion of the western red cedar shingle roof was then followed by the cladding of the building with our largest loglap profile. This quality planed redwood provides an interesting log cabin effect and improves the buildings insulation.

One of the main features of the building design was the “chapel window” which allows staff inside the office to look up and down the main part of the yard to assess the traffic situation! This window also provides the major source of natural light into the office.

6. Planning for effect
Initially we had planned to clad the inside the office in timber tgv or use a quality hardwood ply and then paint the walls in a light pastel colour. However, we were so pleased with the colour and appearance of the chunky douglas fir timber someone had an excellent idea of cladding the framework with white melamine faced MDF.

Using the melamine faced MDF really shows up the beauty of the douglas fir and also provides an easy to clean contemporary surface that is easy to clean and maintain. This white melamine faced MDF is available to order, lead time 7-10 days.

7. Roof detail
the roof trusses were constructed in a traditionl style with a vertical king post rising from the centre of the tie beam. Each truss is supported by the 150mm x 1500mm posts and then further stabilised with curved braces.

Once the building was fully waterproof all of the timbers were allowed to dry without any heating. Allowing the timbers to dry gradually has helped minimise movement and shakes in the framework timbers. All the exposed timbers were then belt sanded to remove any traces of chatter marks made by the band saws when cutting the douglas fir.

8. Fixtures and fittings
The office and showroom were fitted out with oak shelving, beech and Iroko worktops in June 2005. Visitors should find the office light and airy even there we have very little artificial lighting. Despite the frequent foot traffic through the front door the office remains remarkably warm even in winter with minimal heating.

Once again we reached capacity with the office and showroom and from January _ March 2008 the working area was developed further. The front office now features a 7.0 metre counter, more oak shelving and our own character oak flooring.