PROJECTS BY MIKE
Instructions continued:
The Roof
20. Start by printing out an octagon image from your computer that is 4" in diameter. Here is an image you can use http://cahans.com/projects/octagon.jpg. You can either buy a fancy fence post cap or take a scrap piece of 4"x4" piece of redwood and using the octagon image, carefully trace the pattern on the end of the 4"x4" piece to use as the center of your roof top, the 8 sides should be 1-1/4" wide.
21. Set your table saw up for cutting at 45 degrees and carefully cut your 4"x4" into an octagon.
22. Rip the two 2"x4"x8' studs in half then using a miter saw cut them into eight 4' pieces to be used for the roofs frame (roof rafters). Then using a planer or table saw, cut the roof rafters lengthwise so then are 1-1/4" thick or the same thickness as each side of your roof's octagon center piece.
23. Mount your octagon roof top piece onto a scrap piece of 2x4 stud and mount a scrap piece of wood across the center diameter of your aviary. Mark the centers of both the pieces and temporarily screw together as shown in picture. Your Octagon roof center piece should be directly in the center of the aviary with the 8 flat sides lined up with the aviary corners.
24. Now take one of the 4' roof rafters and cut a 30 degree angle at one end. Carefully place this piece in position on one of the eight corners of your aviary and the 30 degree angled end flush against one side of the 4"x4" octagon center piece and rest the other end onto the center of the aviary stringer You will need to adjust your center octagon piece up or down until the roof rafter rests flush against it. Using a pencil carefully mark the roof rafter where it rests on the top of the stringer. Mark it vertically up 3/4" on the end resting off the outside and mark it at the edge where it rests on the inside of the stringer. Remove your roof rafter and carefully draw a straight line between the two marks, this is where you will need to cut a notch out.
25. Using a band saw or saber saw, cut the notch out of your roof rafter you just marked. Create the same 30 degree end and notch in all eight roof rafters using the one you started with as a template.
26. Setup your table saw to cut a 5/8" groove down opposite sides of your roof rafters. The grooves should be cut so they are 3/8" from the top side of the roof rafters. The grooves will be used for the roofs tongue and groove slats to fit into, creating a finished look without any nails or screws showing.
27. Finally, cut the outer ends of the roof rafters 30 degrees parallel to the opposite ends 30 degree angle. The cut should be aproximately 5" from the notches depending on how much overhang you want on your aviary's roof.
28. Mount your roof rafters in place by drilling 1/8" holes through the roof rafter where the notches rest on the stringers and then securing using 2" deck screws. Mount the top end to the octagon center piece using either deck screws diagonally through the ends of the roof rafters or using eight flat metal brackets from the inside of the aviary.
29. Time to start laying down the tongue and groove slats. Starting from the top center of the roof, rest a slat against the octagon center piece and scribe a line where it meets the roof rafters from underneath on both sides. Using your miter saw cut outside the marks 3/8" on each side and test fit into the grooves in your roof rafters. Trim as necessary until the slat fits snugly in between the grooves and at the top most position of your roof. Repeat this process for all the slats using a mallet to lightly tap each tongue into its groove until your roof is complete. I left two of the eight pie pieces without roof slats and used wire mesh over them so sunlight can enter the aviary. You may want to do the same.
30. When you get to your final row of tongue and groove slats its then time to mark the protruding edge where it hangs out of the roof rafters grooves and cut them flush with your table saw at a 30degree angle.
31. Using some 1-3/4" brad nails, carefully nail through the roof rafters and into the last row of roof slats to hold them in place. Sand the ends flush as necessary.
32. Mark and cut the valence for your roof at 22.5 degree angles so the strips of wood fit flush together. Drill 1/6" holes at each end of valence and nail onto edge of roof rafters using 1-3/4" finish nails set with a nail set.
The Breeder boxes
33. The breeder boxes should be a minimum of 6" wide and 5" high so that your finches have enough room to nest. I used 1/2" thick cedar to build the boxes with a 2" diameter hole that was cut down another inch with the bottom rounded for the birds to stand on, see picture left.
I also added 1-3/4" holes with plastic stapled from the inside of the box for windows so that we can peek in and see what's going on inside. You may want to add windows to your breeder boxes as well.
The lids are hinged and have eye hooks with locks in case cats try to come in.
34. To make watering the plant maintenance free and provide clean bathing water for the birds everyday, I hooked a 1/4" line off of a garden sprinkler that is on a timer and ran the line into the aviary.
Using a small terracotta pot and some shallow saucers I drilled a 3/8" hole in each saucer and glued in a 1" piece of clear plastic tubing so that the water will flow directly down into the saucers below and then into the plant. A shutoff valve was installed outside the aviary for controlling the water flow and also for being able to disconnect the line when moving the aviary around.
The frame can be made by cutting a 2x4 stud at 45 degree angles to create steps. You may want to get fancy and create a circular pattern instead of a linear one as shown in picture on the left.
35. Finally add your perches, I made all the perches using branches from trees in the backyard, its not only free but it also looks much better than plain wooden dowels and the birds enjoy pecking at the bark. Four swings were added to the top using pre-bent wire from parrot swings and swapping the wooden dowel for tree branches. A sign can be added by printing out lettering onto a sticky back sheet, then using a knife cut out the letters and stick to a piece of wood. Trace around the letters with a pencil, then remove the stickers. Using a router, route out the letters at about 3/16" depth using a straight narrow bit.
That's it!
Email me at mcahan@hotmail.com if you want to comment or have any questions or tips.
For more great wood projects go to http://cahans.com/projects
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