General: Cut and label the parts as needed, using the Cut List and Cutting Diagram as guides and adjusting for fit. This gate fits an existing opening that measures 40 3/4 inches wide with 72-inch-high posts. You can adjust the measurements to fit your space.
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1 Lay out the gate and build the arched top.
a. For an existing gate opening, measure the width at the top, middle, and bottom. Use a level to check for plumb.
b. On a sheet of plywood or MDF, lay out the posts to full size according to your dimensions and plumbness.
c. Locate the center between the posts and 1 1/2 inches above the top of the posts. This will be the point for all radii of the arch tops and gate top.
d. Following Figure 1, lay out the (01) arch top A, (02) arch top B, (03) gate front/back top, and (04) gate mid top using a beam compass, and attach as shown using glue and pocket hole screws.
e. Lay out the remainder of the gate following the gate layout. The width of the gate will be 1/2 inch less than the opening between the posts. There is a 3-inch clearance at the bottom of the gate shown.
f. Use a beam compass to scribe the inside and outside radii for the (01) arch top A and (02) arch top B assemblies. Scribe the centerline of each arch and lay out the locations for the baluster holes. Cut out the arches and gate tops using a jigsaw or band saw. Lay the gate tops aside for later use.
g. Laminate one (01) arch top A to each (02) arch top B using glue and nails. Be sure not to nail into the locations of the pocket holes. Sand the edges smooth.
h. On one of the arch tops, drill the holes for the balusters completely through the assembly. On the two remaining assemblies, drill the holes 7/8 inch deep.
i. Cut five balusters to 22 inches long. Thread the balusters through the center arch into one of the end arches, leaving 9 1/2 inches between the two arches as shown in Figure 2.
j. Place the balusters into the remaining arch. Using glue and nails, attach the arch/baluster assembly to the (05) arch bases, centered both directions and leaving a 1-inch overhang on both ends.
k. Following the (06) bracket detail in Figure 2, lay out and cut one (06) bracket. Use the first (06) bracket as a pattern for the second (06) bracket. Set the (06) brackets aside for later assembly.
2 Build the trellis assembly.
a. Cut to length and lay out the locations of the baluster holes for four (07) trellis legs as shown in Figure 3.
b. Drill 7/8-inch-diameter holes 7/8 inches deep at the locations marked for the holes.
c. Cut eight pieces of baluster material to 10 1/2 inches long.
d. Cut six pieces of 2 x 6 to 9 1/2 inches long for the (08) trellis spacers.
e. Following the trellis layout in Figure 3, mark the locations of the (08) trellis spacers onto the (07) trellis legs.
f. Attach one (08) trellis spacer to one (07) trellis leg, centered at each of the three marked locations, using glue and nails.
g. Lay the leg/spacer assembly with the (08) trellis spacers pointing up. Insert the 10 1/2- inch baluster pieces into the predrilled holes.
h. Using glue and nails, attach the second (07) trellis leg to the leg/spacer/baluster assembly.
i. Repeat Steps 2e through 2h to create the second trellis assembly.
3 Build the gate.
Note: The gate is composed of three frames—identical front and back frames and a mid frame—with a field of tongue-and-groove 1 x 6 x 8 boards.
a. Assemble the front/back frames from the (03) gate front/back top, the (09) front/back stiles, and the (10) front/back rails as shown in Figure 4, and attach with glue and pocket hole screws.
b. Assemble the mid frame from the (04) gate mid top, (11) mid upper stiles, (12) mid lower stiles, and (13) mid rails and attach with glue and pocket hole screws.
c. Attach the mid frame to one of the front/back frames with glue and nails.
d. Working on the full-size layout, lay out the (14) field boards, working from the center in both directions. Rip the outer boards to width to fit the opening.
e. Use a beam compass to lay out the cuts for the tops of the (14) field boards.
f. Attach the (14) field boards to the front/back frame with glue and wire brads.
g. Attach the remaining front/back frame to the assembly with glue and nails.
h. Sand the outer edges of the assembly smooth.
i. Apply silicone sealant to the joints of the three frames and to the joints at the intersections of the rails and the (14) field boards.
j. Stain the gate.
4 Apply finishing touches.
a. Position the tops of the trellises flush with the tops of the post faces, and attach with glue and 2 1/2-inch screws.
b. Position the top arch assembly so that it overhangs the front of the trellis by 1 inch, and attach with glue and 2 1/2-inch screws.
c. Attach the (06) brackets to the face of the post and the (05) arch base with glue and nails.
d. Fill all holes, sand, and apply stain.
e. Hang the gate, and install the latch.
|arch tops A||1 x 8||3/4 x 7 1/4 x scribed||3|
|arch tops B||1 x 8||3/4 x 7 1/4 x scribed||3|
|gate front/back top||1 x 8||3/4 x 7 1/4 x scribed||2|
|gate mid top||1 x 8||3/4 x 7 1/4 x scribed||1|
|arch bases||2 x 6||1 1/2 x 5 x 25 1/2||2|
|brackets||2 x 8||1 1/2 x 7 1/4 x 12||2|
|trellis legs||2 x 4||1 1/2 x 3 1/2 x 72||4|
|trellis spacers||2 x 6, 2 x 8||1 1/2 x 5 1/4 x 9 1/2||6|
|front/back stiles||1 x 4||3/4 x 3 1/2 x 57 5/8||4|
|front/back rails||1 x 6||3/4 x 5 1/4 x 33 1/4||4|
|mid upper stiles||1 x 4||3/4 x 2 5/8 x 25 5/8||2|
|mid lower stiles||1 x 4||3/4 x 2 5/8 x 28 7/8||2|
|mid rails||1 x 6||3/4 x 3 3/4 x 40 1/8||2|
|field boards||1 x 6 tongue and groove||3/4 x 5 1/2 x scribed||7|