- 1). Lay out timbers on a big level work area, preferably concrete. A big warehouse is ideal. Measure timbers to fit the dimensions of the building and lay them in their proper positions, timber posts at corners and beams at the top. Put any internal posts in proper position as well, if any are needed for long spans. Cut timbers where needed to get exact fits, with beams fitting inside timbers at the top.
- 2). Cut mortises and tenons. Mortises are big slots 1 1/2 or more inches wide and 4 or more inches long. Tenons are tongues cut in the matching beams to slide inside the mortises. Corner posts will need mortises on both sides to accept beams from both side and end walls. Use a reciprocal saw to start the mortise and tenon cuts, then finish with chisels and a hammer or mallet to get the final dimensions. Tenons must fit securely into mortises.
- 3). Make "dovetail" mortises in the tops of side wall beams to hold roof joists. These are mortises with angled sides cut a couple of inches deep into the top of the beam so a matching tenon on the joist will slip into that joint and rest on the beam. Cut these mortises with chisels and a mallet. Cut tenons on the ends of all roof joists, slightly smaller than the mortises so they will slide in place easily. Tenons can be rough cut with a saw and finished with a chisel.
- 4). Test fit all mortises and tenons. Once those are good, mark spaces for knee braces on both sides of every timber. These will be smaller mortises and tenons, cut into the bottoms of the beams and down the sides of the timber posts to hold braces (usually of smaller timbers) at a 45-degree angle to support the beams.
- 5). Drill holes through all mortise/tenon joints, two holes on each post connection and one on each knee brace connection. Drive hardwood pegs completely through these holes with a mallet. Leave the peg ends or cut them flush with the post and beam sides. If wall timbers are made in a warehouse, mark the pieces for position and fasten connections after assembly at the job site.
- 6). Erect walls one at a time. This will require a lot of help or a crane. Set wall posts upright and level and brace with 2-by-4-inch boards nailed temporarily to the timbers and to stakes in the ground to support them. Once one wall is up, erect a second wall, sliding tenons into the pre-cut mortises and fastening with wood pegs. Do this until all walls are erect and secured. Fit roof joists into the side wall mortises and secure by driving wooden wedges into the sides to make the joints tight.
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