Cut our spars to 46 3/8" and installed them 12" apart on flat areas and 6-8" apart along the curve. I used the drill press and the 3/8" spade bit and drilled six holes into each spar so we can run the wiring through the ceiling.
Spars were installed with a 2" exterior screw through the outside except for the bottom two spars. We used pocket holes and installed them inside out since the bottom half of the exterior will be exposed since we are doing a two tone design.
We got our Maxx Air fan the other day and it fits the 14"x14" framing we built for it. Since our roof is not going to be the minimum 2' thickness, we will be building a small interior frame to help with the depth of the fan.
Total time spent Day 13: 2 hours
Total project hours: 50.5 hours
Next day we put in our interior ceiling! The width of our interior is exactly 46 1/2" so we took the circular saw and attached the guide and buzzed off 1 5/8" so we had a bit of wiggle room. Our radius is 25" so we figured we could bend our board vertically instead of horizontally so we would have less waste. 1/8" plywood (luan) bends better one way than the other.
And we found the bad way.
Next piece we took much slower and had to wet it to get it to bend along the spars. Still regret doing it vertically as it was a nightmare trying to get it to move with the friction of the ceiling. Once I got it an inch or so away, Dan applied the polyurethane glue and I got it against the spar and installed a 3/4" screw on each end of the spar close to the interior walls.
In one frustrated effort, I managed to crack it. 🤦🏻♀️ I'm thinking about putting in a strip of wood like I was covering a seam to cover it up. It's also not crazy noticeable if I don't shine line directly on it. It didn't fully crack on the inside so I slathered glue all up in the crack and it seems pretty stable since it had time to dry.
Total time spent Day 14: 3.5 hours
Total project hours: 54 hours
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