As an example of how much time goes into the construction of each gate, below shows how the frame of the gate is produced.
Mortise and Tenon Joints:
After marking the position of the mortise, the lines are squared around the timber. We then calculate the centre in which the mortise hole will be made.
The timber is then clamped to the mortiser and positioned in place. A 50mm deep hole is then cut into the side rail. This process is repeated until the rectangle shaped mortise has been formed. This has to be done slowly, at a small section at a time to prevent the timber from splitting.
Above shows a before and after shot of the process. The timber starts (square edged) and is cut to form the tenon. This is the vertical pieces of the frame and both sides are cut to have tenons on each end.
Once the tenon joint has been formed, the shoulders are then marked and removed using a bandsaw. With a Driveway Gate, the whole process is repeated 8 times for each set.
Now we have a completed mortise and tenon joint. We have to "dry" test the joint to ensure it fits perfectly. This is repeated on every joint for the frame of the gate.
Strong poly urethane glue is then applied to the mortise and the tenon.
The joint is then checked to make sure the angle is square. This is repeated on the whole frame. Once the frame is correct, long clamps are put in place until the glue has cured, this process takes 6 hours before the clamps can be removed.
One of the ways we differ from other companies is by adding the dowel joint. The dowel joint ensures that the mortise and tenon joint has no way of pulling apart.
Once the gate has cured, the clamps are removed. The position for the beach dowel is then marked. It is then drilled to a depth of exactly 45mm through the timber. This is done from the rear side of gate so its not visible from the front.
The Dowel hole is filled with poly urethane glue and the beach dowel is entered. Once the glue has set, the dowel is then sanded down to a completely smooth finish. Again, this is repeated for all of the frame. The dowel joint remains visible from the rear side of the gate.