One of the most time-consuming tasks in home building is cutting a roof. Sometimes, it can take as long to cut and frame the roof as it does to frame the house's rest. It can also require a lot of space to get the job done. It is in one's best interests to plan during construction to be ready when it comes time to cut the roof.
Whether the roof is a simple gable roof or a complex roof with multiple hips and valleys, you want to be able to cut more than one rafter at a time. Sawhorses become a valuable commodity during the roof-cutting phase of construction. Cutting a half dozen or more rafters is what you want to try for. There are a few options available for the roof cutter.
If you only have one set of horses, nail an eight-foot 2x4 flatwise to the top of them. This will allow you to mark and cut six or more rafters depending on their width.
The second option is to use two pairs of sawhorses. Just like the previous option, nail a 2x4 flatwise over the top of two horses. In this instance, you are not limited to an eight-foot 2x4. You can use an 8, 10, 12, or even a 16' 2x4, depending on how much room you have to work in.
The third option is to make your sawhorse out of a 2x10 and put legs on it, just like a normal sawhorse.
Another time-saver is to make a rafter pattern. Pick the straightest piece of lumber from the rafter material to do this. After you have marked all of this on the 2x, carefully and accurately cut the rafter.
The next move is to nail stops to the top of the pattern. Cut two pieces of plywood about 6" long by 2 1/2" wide. Nail one to the top of the 2x about 2" from the upright cut, letting it hang over both edges of the 2x one-half inch. Nail the other piece just above the birdsmouth. You now have a pattern to mark the rest of your rafters without measuring each one.
When you are ready to start cutting the rafters, lay as many boards on the horse as possible and have enough room for the saw to fit between each one. When laying the boards on the horses, have all the crowns pointing in the same direction (When looking down at a board while flat most boards are bowed one way or the other. The convex side would be the crown). Take the pattern and lay it on top of each board with the plywood stops resting on the crowned edge and mark them.
You are now ready to cut the rafters. When making your cuts, cut the pencil line. Cut the upright cut first and then move to the birdsmouth and tail. Depending on how many rafters you are cutting, you may have to slide them back and forth so you are not reaching over too far to make cuts with the saw. When cutting the birdsmouth, it is okay to over-cut it to remove the material.
Homebuilding and cutting rafters can be dangerous. Always exercise caution and safety when framing or using a skill saw.
Mike Merisko (C) 2006 sawkerfs.com
