I’m working with S4S timber to build a 14’ x 14’ square gazebo. My posts are 6x6 (5-1/2” x 5-1/2”). My knee braces are 4x6 (3-1/2” x 5-1/2”). All wood is cypress, being in FL. Per the books my tenon is to be 1/4 but no larger than 1/3 the width of the knee brace, so it will be 1-1/2” wide with 2” shoulder and is in a 1/2” housing.
The dilemma is the tenon length, when I offset it 2” from the reference side. These posts are all corner posts and the knee braces come together in to it at 90deg at the same elevation for symmetry. If the tenons are to be 2” long, the two of them will overlap by 1/2” in the middle of the post.
I see several solutions, some require more work than others. 1. Simplest: Reduce the tenon length to 1-1/2” to 1-3/4” or cut the overlapping corners on the two tenons 2. Offset the tenon more towards the reference face (external wall) and would need to cut housings in the post on both side of tenon. 3. Reduce the width of the knee brace on the planer from 3-1/2” down to 3”. That will make the shoulder 1-1/2” and the tenon 1-1/2”.
If I keep the knee braces at same elevation (preferred), any issue with all the meat being removed from the post at the same elevation? My knee braces will be 30x30 (42.43”). Already have the material which are 4 sticks at 8ft long, so if I make two of the knee braces longer, the other two will need to be shorter than 30”. Reading, that is already on small side.
