Horse Barn Cupola Repair

This project employed many facets of carpentry: from geometry and framing, to surface protections and finishes.

The repaired cupola after the painters were finished

To begin, we constructed a semi-permanent platform system that was hung using steel ridge hooks and rested on foam pads. It was critical to protect the asphalt shingles during the heat of the day from heavy footsteps, and the constant friction of the resting platform. From this platform were able to deconstruct the façade, assess the structure, and begin the repair.

Installing windows on the large cupola from the scaffold

These octagonal cupolas were originally constructed on the ground in three sections—base, vents, and roof—then presumably lifted by crane to the ridge for installation. This process played a role in its repair, as the framing was not continuous from the bottom plate to the top plate.

Installing the continuous studs

Reframing a cupola face from the scaffold

We replaced the framing members one at

a time on the large cupola to ensure all the weight was continuously supported.

The smaller cupola allowed us to reframe one entire side using continuous members, while diagonal bracing maintained proper weight transfer from the copper roof to the barn ridge.

Once every compound angle was cut and every 2x4 replaced, the structure was then clad in plywood for lateral stability. The plywood also served to create a flat plane for the finish materials.

The finish materials were Boral and Hardie panels, which are very stable synthetic products. Additionally, they’re highly resistant to moisture and certain to save our clients maintenance, and money, over the next 50 years.

HEPA dust filtration for the table saw and Festool track saw

The table saw was primarily employed for the vertical trim (Boral) on account of its repeatability, as each piece met the next with a 22.5 degree bevel. The broad surfaces (Hardie panels) required long precise bevels, so we made use of our favourite tool: the Festool TS55 tracksaw, and its companion CT36 Dust Extractor.

Progress on vent construction for the smaller cupola

Protecting our lungs—and those of the nearby prize thoroughbreds—was critical, which is why our HEPA dust extraction system was essential.

A sunrise at Crestwood before work began

Projects like this are humbling to work on, as the beautifully groomed grounds catch your breath, gently reminding you of your place in this state’s unique history. Many carpenters have come before us, carefully crafting these horse barns all over central Kentucky.