Join us on our journey
In early 2023 we were asked if we could build a replica of a 250 year old oak and flint barn.
Its not everyday that a request like that comes up so we looked into what would be involved.
After a lot of research we decided that it would be possible and started the design.
It started off with many drawings and changes until the final design was agreed, then the hard work started.
Stage 1
It was decided that the bracing would be taken from naturally curved oak boughs rather than cutfrom straight cut timbers and aged.
timbers used came from the New Forest and from a farm in the Liphook area.
These were then taken to a small sawmill in Dorset to be cut and returned to our workshop.
The braces were then cleaned and debarked using a traditional draw knife and a tenon was cut on each end.
As the braces were from naturally curved timbers they were all different lengths which caused issues further down the line.
Stage 2
The oak was ordered for the frame, wall studs, wall boarding, rafters and roof boards.
With a total weight of 37 tons it was a huge amount for a single building.
As the building was designed to look old none of the oak needed planing...thankfully.
We made all the pieces for the barn frame in our yard with all joints cut except the brace joints and delivered them to site.
As all the braces were natural and different lengths they all had to be fitted and jointed as each was required.
There were over 90 braces in the total build. The frame was raisedover the summer and the walls were studded and boarded.
Stage 3
Finishing Touches
The roof was boarded at the end of summer and the building was handed over to the roofers.
17,000 tiles later it was nearly done.
The last thing to do was to make and install the doors.
They were made to age in both colour and structurally.
The frame is made from kiln dried oak to give the doors a chance of staying straight and the boards are green oak.
This was to allow the boards to bend and shrink to give the look of very old doors.
The doors are 120mm thick with 60mm of solid green oak board, they weigh in the region of 300kg each leaf.
Happy Clients
The barn was finished at the end of October 2023 and delivered exactly what the client wanted.
During the build we learned a lot and we are now ready to do it again.
So, if you have a need for or desire to own a replica ancient barn please get in touch we would be happy to help.
