How We Do It
Once the stacked shell is scribed (see below), then we cut out
the timber between the scribe lines of each log. We start with
a chainsaw to remove large pieces, and then finish with sharp
chisels and fine sanders. We work to 1 or 2mm tolerances on log-to-log
fits.
In this photo, Robert is cutting out the long groove ("lateral" groove) with a chainsaw--this is how we create a tight fit between the lengths of the logs.
Cutting Grooves and Notches
After the stacked shell is scribed we take the stack apart and
set each log close to the ground so we can cut out the notches
and grooves.
We use the "Beckedorf double cut groove" and here you can see Gray cutting the Deep V on top of the log.
Saddle Notch Corners
As shown here we use compression-fit, underscribed, saddle-notch
corners. This is state-of-the-art log construction.
Overhangs or "Flyways"
You will see several different styles of log ends outside the
corners in our houses. We call these the log overhangs or flyways.
In this photo the flyways are all the same length, and have a
traditional "chisel" shape ends that alternate left
and right.
In the photo below is another style-- the flyways alternate in and out in length: long, short, long, short.
Electrical Holes
To make reassembly even easier, all vertical electrical holes
inside the log walls are predrilled, and flat spots are provided
for electrical boxes and cover plates. You provide us with an
electrical plan that is sufficient to show the location and size
of all these items. As an option, we can even mortise holes for
recessing the boxes - simply provide us with detailed electrical
plans and spec sheets.
"Hurricane" Rod Holes
Wall height holes for threaded rods are standard in our log home
shells. If you would like to discuss a different system, please
consult us. Your engineer may want to discuss wind and seismic
loadings for your area with us.
Roof Systems
Our log shells are delivered complete with all roof logs pre-cut,
hand-notched and ready for assembly. Each top-plate log, purlin
and ridgepole have roof-pitch flats already made. We also offer
state-of-the-art structural log trusses of round logs, non-structural
log trusses, log post-and-purlin roof systems, log common rafter
systems, and much more! Simply provide us with blueprints including
roof plan and, if they are needed, engineered shop drawings,
and we'll handle the rest.
Weather-Resistant Gaskets
To protect your home, and keep it warm in all climates, each
long groove (lateral) and corner notch has rubber gaskets ("seals")
pre-installed by us. We use only the finest rubber seals and
fasten them onto both the inside and outside edges inside all
long grooves, and in the inside perimeter of all corner notches
and stub-wall notches.
These gaskets are specially designed by Natural Log Homes and are manufactured for us by a Christchurch, New Zealand company. They are similar to the seal around car doors-- which keeps air and rain out even at 100 kph.
Our rubber seals are made of EPDM (a high-performance synthetic rubber) and feature 3 separate flexible fins of varying lengths that provide a TRIPLE barrier air, rain, and light. Just as windscreen wipers effectively wipe water, these seals with 3 fins outperform other seals.
Bulb-type seals allow water in by capillary action. Our seal PREVENTS capillary action.
Our gaskets are the best-performing, most flexible, most weather-resistant gaskets available. In our experience, these gaskets have virtually eliminated air and water leaks. We're happy to provide gasket samples upon request-just ask us!
We are experts at structural roof trusses made from logs. This one is going to cover the entry verandah of a log house. We build it near the ground so it is easier to construct, then once it is completed we put it up on its posts to create the roof.
Floor Joists
We can build loft, or first floor, log joists, and support beams-complete
with all floor-groove cuts. Each log joist is shipped pre-flattened
and fully notched into walls and beams, as needed.
Window & Door Openings
All door and window openings will be cut and sanded, unless you
specify otherwise, and splines ("keyways") will be
cut for installing angle-iron keys.
In this photo you can see window openings, also note extra- large timber valley rafters and log ridge beams.
The log ridges are supported by a forked tree--see the photo below about "special logs."
Here a window opening is double-checked that it is plumb and square. All these cuts are made by hand - - and they HAVE to be, because there is no machine to do the craftsman's job.
Special Logs
We watch for opportunities to use special logs -- forked trees,
bent trees, "doglegs", burls, and more. We like their
unique and beautiful natural shapes.
And of course we like the challenges these unusual "character logs" present to us as craftsmen!
Here, a 2-story forked tree supports double-ridge logs that span north-south. There will also be another ridge log that spans east-west that sits on top of the forks!
This forked tree is the log centerpiece of the lounge / great room-- we think it is a natural log sculpture.