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Preparation is everything. If you are building
your own poles you will need to purchase pole stock (wood!) Look at the
chart above to determine what you need for your marquee. Use these
dimensions only as a guide and a place to start. As you read on you will
notice we have filled in the dimensions for your unique tent. We are going
to describe how we would build your pole set, if you choose different
dimension lumber be sure to factor that into the dimensions given. Main Pole System: We use Douglas Fir for the stock in our main
pole system. Douglas Fir is stable, does not check or twist as much as some
soft wood and is very rot resistant. We use “4x4”s (measuring
an actual 3 ½” x 3 ½”). Pick them carefully at
your lumberyard remembering you only want to do this once and good poles
will cost as much as knot filled, twisted poles.
Vertical Poles: For a “quick” set of vertical poles
set your table saw to 2 ½” and rip your pole stock to
2½”x 2½”. Reset the fence and blade to rip the
stock to an octagonal shape. Find the overall length of your upright from
the dimensions we have supplied, subtract the thickness of your ridge pole and
cut the pole to length. Drill a ½” hole directly into the
center of the top end. Cut a ½” piece of round stock steel to
10”, radius the ends and place into the hole. Make two. For a fancier set of poles adjust your
table saw to rip your stock to 2 5/8” x 2 5/8”. When complete
run your stock through a thickness planer to a finished 2 ½” x
2 ½”. Find the overall length of your upright from the
dimensions we have supplied, subtract the thickness of your ridge pole and
cut the pole to length. We like the look of poles with a “stop”
so set your jointer fence at a 45 degree angle and the feed table to remove
enough wood to make the pole octagonal after four passes. BUT FIRST, figure
where you would like the stop to be, usually 9 to 12 inches from the end.
Run the stock into the jointer stopping at the same point on each cut and
lifting directly up from the table. CAUTION: this is incredibly dangerous
as it leaves the cutter blades exposed and ready to take off a finger tip,
etc. Pay attention, you will only need poles once in awhile but you will
need your fingers every day. Cut a ½” piece of round stock
steel to 10”, radius the ends and place into the hole. Make two.
RIDGEPOLE: A “quick” ridge pole may be made
starting with a “4x4” Douglas Fir ripped to 2 ½” x
2 ¾”. Cut to length. Chamfer the two top edges by setting the
table saw at a 45 degree angle and ripping again. Measure the “short
point to short point” and cut the ends to shape. Measure, mark and
drill the holes using a 9/16” drill bit completely through the pole. For a fancier ridgepole adjust your
table saw to rip your stock to 2 5/8” x 2 7/8”. When complete
run your stock through a thickness planer to a finished 2 ½” x
2 3/4”. Cut to length. Chamfer the top two edges on a jointer set at
45 degrees. . Measure the “short point to short point” and cut
the ends to shape. Measure, mark and drill the holes using a 9/16”
drill bit completely through the pole. Sleeves: If you are using a sleeve on
your ridgepole you now want to cut your pole in half. Fit a sleeve to a
pole piece to determine just how much larger your pole is than the sleeve.
Set your jointer to take the minimum off of each face. Mark the table so
your cut is 7 1/2 inches on each face. Fit the sleeve and repeat until the
sleeve fits snugly. When you are happy with the fit leave the sleeve on one
pole section, drill a hole to accept a nail or screw to secure the sleeve
in place. PERIMETER POLES: (OPTIONAL) Douglas Fir is our choice.
“2x2” (measuring an actual 1 ½” x 1
½”). Hand pick them one at a time for poles you want to work
with and look at. You need a bunch. Set up a system so
you are not doing them one at a time. First; cut each pole to the length we
have given you. Second; drill a 3/8” hole in one end roughly 3”
deep. Third; set up a router or shaper table to cut the pole stock with a
45 degree chamfer bit. Starting the cut about 9” from the end of the
pole, chamfer the edge to a point 9” from the other end. Repeat for
each edge (4 times for each pole). Cut 3/8” steel stock to 6”
pieces. Radius the ends and place one in each perimeter pole. Yes, you may make a
“quicker” set by eliminating all the chamfering and leaving the
stock just a “2x2” but it would not be near as impressive. |
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