During the summer months this year the museum forge was closed due to dry conditions, affording the time to work on other projects. This 4×16′ timberframe shed provided an opportunity to further develop and practice basic techniques of Japanese structural joinery. As with the kajiba project, the main inspiration for aesthetic and design is the humble Japanese inaka naya (納屋) style of a century ago. From rough sawn lumber the preparation of parts took four weeks, the frame and roof assembly one day, and the yakisugi siding and doors about a week.
Using a large post kanna made from reclaimed materials to smooth the large cedar beams before marking.
Bamboo sumisashi (墨刺, ink pen) and permanent ink are used to mark the layout for the joinery.
The hozoana (ほぞ穴, mortices) and arihozo (蟻ほぞ, dovetails) are cut on the red cedar dodai (土台, sill/floor beams), along with the koshikake for the aritsugi (腰掛蟻継, lapped dovetails) for the cross pieces, and the running koshikake (腰掛, step) to support the floor boards.
Hozo (ほぞ, tenons) are cut on the fir hashira (柱, posts), the smaller ones preserve the strength at the corners.
Hozoana (ほぞ穴, mortices) are cut into the fir hashira (柱, posts) for the koshinuki (腰貫, hip tie beams).
Hand planing reveals a lovely variety of grain and colours found near the bark layer of this locally milled fir.
The nuki (貫, tie beams) slide into sloped mortises in the posts.
Making compressible nukikusabi (貫楔, wedges) from red cedar scrap.
The nuki (貫, tie beams) will be locked into their mortises using kusabi (楔, wedges).
The hanamoya (鼻母屋, roof beams), also serving as shikigeta (敷桁, wall plate) in this lean-to construction, are cut to receive the taruki (垂木, rafters) at the angle of roof slope.
The floorboards are cut to length and charred to show the grain in yakisugi (焼杉, charred cypress) style.
Laying the cornerstone for the foundation, each post will have a stone directly below it.
Soseki (礎石, base stones) laid, along with filler stones to close the gap at the front of the foundation.
The sill corner locked together with koshikake-kata-arikake (腰掛片蟻掛, stepped corner dovetail) which forms the fourth side of the mortise for the corner post.
The posts and beams raised, the nuki are sitting loosely and not yet wedged to allow adjustments during assembly.
The floating itajiki (板敷, floorboards) in place.
View of the fumi-ishi (踏石, entrance stepping stone) and yakisugi floor.
Truing the posts using a plumb line and squaring the roof.
View from the rafters.
Wedging the nuki (貫, tie beams).
Installing the taruki (垂木, rafters).
View of the frame assembled.
Installing the purlins.
Structure is ready for the totan roofing material.
Detail of the roof at the back wall.
Some lovely colours in the western red cedar for the door frames.
Cutting the small mortises and through-tenons for the door frames.
Assembling the door frames.
Assembling the pressure-fit door frames by tapping evenly.
View of the top rail, the tenons go fully through to give as much strength as possible.
