How to efficiently install dozens of decorative rafter tails on a structure
In short: When a Dutch Colonial design requires dozens of precise decorative elements, traditional hand-cutting can become a massive bottleneck. Builder Jeff Sweenor found a way to bypass days of manual labor by using CNC milling to ensure perfect consistency and significant time savings on the job site.
In a recent project in Westerly, builder Jeff Sweenor faced the challenge of installing a high volume of rafter tails. The architectural drawings for the Dutch Colonial structure required 62 tails along the sidewalls where the gambrel roof sits to create a specific eave detail. However, the scale of the project was even larger, with approximately 150 total tails required across the entire house. This specific architectural detail was observed during a recent site visit to a project located in Westerly. The sheer volume of components necessitated a highly efficient approach to maintain the construction schedule.
The installation method relies on a specific assembly to ensure structural alignment. According to the drawings, a continuous 2x6 cleat holds the 62 rafter tails, which are 14 inches wide and feature a soft slope. The tails undergo specific milling to ensure their base matches the cleat's bottom edge, creating an uninterrupted nailing area behind the soffit. The design specifies that these components should be 14 inches in width. This precise measurement ensures the eave detail meets the exact requirements of the original blueprints.
A beveled 2x6 ledger at the top strengthens the structure, offering constant nailing points for two 3/8-inch plywood layers. Finally, a beveled 2x sub fascia ties the front of the rafter tails together and provides nailing for the fascia. For Sweenor, opting for CNC-milled products over site-built options provided better quality and cost-effectiveness, saving a carpenter two full days of manual work with a jigsaw and circular saw. By choosing pre-milled parts, the builder avoided the tedious process of using a circular saw and jigsaw. This strategic decision allowed the crew to focus their energy on other essential tasks.
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Sources
- Summary by Intellect · source: How to Apply Rafter Tails | Pro2Pro | This Old House
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