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After filling the pond, we used 2 boards as a bridge. It was
quite exciting - when you drank too much coffee, or when you were trying
to carry something heavy!
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View from the back of the pond looking toward the patio and
bridge. When you buy a bridge, you expect a 6 foot bridge to span 6
feet. It turned out that it only spanned 4 feet, so we decided to
use all the parts we could and re-cut the railings and curved support
members...
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The cutting diagram was laid out in AutoCad, and we purchased a 4x8'
sheet of marine ply 3/4" thick, as well as some clear cedar for caps
on all the pieces. In the end, we replaced the vertical posts
too! We were able to use the cross planking and the feet!
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The only accurate way to cut partial circles is to build a jig.
Given the sheet of plywood was 4x8', it took some 2x4's and more plywood
to create the jig.
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The jig had to be bolted to the marine ply, and the whole assembly was
swung in an arc using the band saw to cut off pieces.
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Here's the first cut being swung through the band saw. A total
of 4 large rails (which carry the weight of the bridge) and 8 handrails
had to be cut. The band saw blade was quite dull by the end!
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Close up of cutting one of the hand rails. There are 2 hand
rails on each side, and each one had to be 1 1/2" thick , so we had
to cut a total of 8. The structural members were also 1 1/2"
thick, so we had to cut a total of 4 of those.
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Here's the first structural member!
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All 12 of the cut pieces ready to be glued.
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The pieces were glued together using special outdoor epoxy resin in
sets of 2. There's never enough clamps for a job like this, and the
gluing took 3 days!
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Top caps of clear cedar were cut slightly wider than the 1 1/2"
pieces, then slotted with a dado. These caps were pressed to the arc
shape and glued into place over another 2 days. The pieces were
drilled using the short originals as a template, and the bridge was
assembled, and stained.
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Our new bridge in the sunset, now spanning the entire 6 feet of the
connector between the two ponds. The bluestone patio and the
foundation rock were drilled, and the bridge firmly bolted into
place. It's a great viewing platform for watching the fish!
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