Bespoke Gutter - Concept to Completion
The brief - Create a timber framed gutter lined with copper that will hide the structural steel work above an Orangery, the design of which shall suit the existing timber work around.
1. 2D & 3D modelling to create the desired design
- Any complex design will start with a 3D representation that can highlight potential problems and aid in creating a great design that can be shown to a client and easily altered to fit with any requirements or requests before any material is cut. In the 3D rendering different finishes and shapes can be displayed in varying lights to replicate any period of the day.
2. Technical drawing production
- Once a design has been agreed upon a technical drawing can be produced that describes all the dimensions and profiles required to produce the physical objects. At this point an accurate costing can be created from the bill of materials. Once this document has been produced and all fees have been agreed materials can be ordered and work can start.
Above - One in a series of technical drawing produced to describe the design of the bespoke gutter
3. Production Stage 1
- The stock timber is allocated a component and cut oversized.
- These pieces are then planed square and thicknessed to finished sizes (Should any pieces require jointing together to create larger sections this happens before they are completely brought down to finished sizes).
- Decorative moldings, grooves and rebates are then added whilst the timber is oversized in length (This means any end sections of the timber which is most vulnerable to damage can be removed after all the profiling has been achieved).
- The ends are then squared and the components are cut to length.
- Mortises are cut in the front base rail to accept the curved supports.
Above - Timber at the end of production stage 1
4. Creating Curves
- This design required 13 identical curved components that would make up the support for the front of the gutter.
- To create the components in house a jig was required that could accurately reproduce the curved shape multiple times.
5. Glue up, Sand & Paint
- Polyurethane glue is applied to the components and left to set. Once dry the expanded glue is removed.
- The profiles are then hand sanded and any imperfections are filled.
- Two coats of undercoat are then applied.
6. Production Stage 2
- Now that the main components of the structure are completed the second fix items can be measured up and brought together.
- The ply for the back is cut to size and rebated to add a locating tongue to base, it is then sealed.
- 5mm column wrap flexi ply is cut to size and painted.
- The end caps are made using a 1:1 template.
- The cap that connects over the ply back joints and the blocks that raise and support the base of the copper are produced and painted.
- Fixing blocks to take the front of the flexi ply are then added and everything is glued and screwed together using only stainless steel screws and polyurethane glue.
7. Copper Lining
- The copper lining is cut, bent to shape, riveted together and finally soldered.
- The lining is then subjected to a water test to make sure all the solder joints are sound.
- It is then fitted into the Accoya frame being secured in place by the back cap being glued down to the ply back.
- Copper tie bars are finally added to relieve the stress exerted on the front curved brackets.
8. Fit
- The finished gutter is lifted into position.
- The brackets are brought up and fixed below.
- Finally screws are added into the structure behind the gutter to secure the top in place.