Work flow kind of went like this:

Model timbers in SketchUp. I sized the timbers in SU to allow for 2 theo numbers for each timber, one being the outside dimension, and one being the reduction dimension. The outside dimension was called out small enough that it would also be entirely inside the as is timber so that I could have a theo relationship to work with.

To lay the valleys out, I first milled a flat reference face on the top (which will eventually have the backing cuts cut out of it). This gave me a face where I could snap out both the reduction and the exterior theo dimensions. After setting the timber in space, plumb and level, then I could use a laser to dance the lines around the timber.

Using the shops that were generated from the SU model, I knew what all of my angles were, and I used the snap lines to place these lines on the timber. The trick was to have all the reductions modeled beforehand, so I could ensure that, when viewed head on, would show a 1" of the tenon, and then 1" that is the bevel. Having that modeled allowed me to determine length along the valley that I need to have so that it looks like 1" when viewed straight on.

Once I laid out the sides, then I could dance the lines across the bottom, too.

Since I only generated shops for one side, I laid everything out on the mirrored valley at the same time, so I could keep the likelihood of getting confused to a minimum.

Now, still with the flat reference face on, I cut both ends of the valley. Once everything else was cut and finished, then I sliced out the backing cuts on the top face.

Am I liking the work so far? Am I a frustrated timber framer? Well, that depends. Firstly, I am really happy to be working, so that is is a positive. Second, as far as I am concerned, getting to model the job and generate the shops is the part of the job I really want to do, so that is definitely a positive. As far as cutting the pieces, I have always been the guy who wants to cut the hardest (most interesting) parts of the job. In this instance, since I had so much time into the pieces, just in the computer, everyone took one look at the shop drawings and told me to get my butt over and cut the pieces since I was more dialed in than anyone else. And, since most of the guys I work with have only known me mostly as the computer guy, even though I was a builder and contractor for 16 years before I even knew how to check my email, it was good mojo for me to step up and cut some of the most challenging pieces in the job.

I find it really helpful, now that I am working on the computer so much, to get out into the shop and cut wood fairly regularly, as it is so easy to forget that the computer pieces are really representing expensive, heavy, and time consuming sticks of glorious timber. It is good to remind myself how much time and effort it takes to move these guys around, and cut them, and set them in space, and all the other myriad steps that go into the cutting. Keeps me realistic and humble, you know?

cheers, Chuck