How to Build The Ace Clubhouse

Steps Continued: 3 and 4

Step 3: Building the roof

Various portions of the roof will require two adults to complete. The center roof beam is made from an uncut 2" x 6" x 8' . You must attach the roof beam from the peak of one side wall to the other. Raise it as high as it will go without protruding above the side walls, and screw it into place through the side wall paneling on both sides. Next, attach the eight angled joist hangers to the roof beam in an arrangement corresponding to the notches you cut in the front and rear walls (as described above).

The rafters are also 2" x 6"s, each with an end cut to 60 degrees in order to meet the roof beam. We chose to cut our rafters so they would be more or less even with the edge of the roof at 3' 1-1/2" Using the jigsaw, we cut a simple scroll curve to the end for decorative effect (See photo 4). You may want your rafters to extend beyond the edge of the roof, or you may want them hidden short of the roof. Therefore the length of the rafters can vary depending on your taste. Once you have the 8 rafters cut, slip them into the joist hangers and through the notches you cut in the front and rear walls. Before you screw it into place, you should check to see that the rafter is flush with the top of the wall where it passes through the notch. If the rafter sits too high, there will be a gap between the roof and the wall. If you need to, you can cut the notch a little deeper with a hand saw. When all the rafters fit flush, screw them into the joist hangers (See photo 5). This is a good time to remind you not to worry if a few things don't fit perfectly. Regardless of your skill level, it's pretty common for there to be gaps here and there with all these angle cuts, and after all, that's why they invented trim.

For added support, we attached 2" x 6" pieces to the inside walls between the studs. You can attach the rafters to these using the L-brackets (See photo 6).

Now you are ready for the roof. As with the rafters, the extent of roof overhang is a matter of taste. You'll need a second adult for this part anyway, so you might want to experiment with different looks by sliding a piece of plywood back and forth on the rafters. Your child is the ultimate foreman on this job, so once he or she approves, simply cut the plywood to fit, and attach to the rafters using 2" screws.

Step 4: Shingles, Trim and Paint

To protect the roof before shingling, it is important to cover it with roofing felt. Cut one piece for the bottom of each side and staple them into place. Use another sheet to cover the peak, overlapping the two side pieces. Shingling is relatively easy; just make sure you have a ladder tall enough to allow you to reach the peak without having to lean too far out. Shingles come in various styles, so follow the manufacturers instructions on the package. In general, you will want to allow enough overlap to keep rain from getting under them to the plywood (See photo 7). Once you have nailed all the shingles in place, check to make sure none of the nails are protruding through to the inside. Any nail points coming through should be carefully hammered over, or cut off using a portable grinder.

Shingling Instructions

Starting at one of the bottom corners, attach a shingle with two roofing nails. Then work your way across the bottom edge of the roof, butting each new shingle evenly against the last. You will need to cut the last one to make it even with the side edge of the roof. Just score it with a utility knife and snap it. The second row overlaps the first. The felt has lines running across to let you know how far to overlap each row. Just make sure you stagger the shingles so the seams don't line up and allow water to penetrate to your roof. (Like laying bricks). Do this for both sides up to the peak. For the peak itself, we cut our shingles in three pieces (at the slots). Fold them across the peak and nail at the corners. You can start at each end, overlapping toward the center, or just work from one end across to the other. Another option is a pre-fabricated peak cover.

We chose plain 1" x 3" boards for the trim around the windows and doors. With plain boards, you can simply cut the pieces to long enough to overlap on the top and bottom. For something a little more decorative, you might want to try your hand at one of the various molding styles available. If you decide to use molding, just make sure you have a miter box, or a chop saw that can be set to 45° for the corners. You can also dress up the corners of the clubhouse in this same way.

The foreman on our job (Stuart, age 8-1/2) wanted a few extra touches to his clubhouse to give it a special look. We used the jigsaw to cut a simple scallop pattern into the 1" x 4" boards, and screwed them under the gable end of the roof on each side (See photo 8). The gates on each door were created by making a box from the leftover 1" x 3" trim pieces, then cutting and fitting the deck spindles. When measuring your gate size, make sure you allow enough roof for the door to swing open without rubbing the jam. Hang each gate using two 3" hinges, and attach one of the hooks to the other side. Two wooden ball finials attached to the roof peak finished things off.

All that is left is painting. This is where a foreman of any age can really get to work. The clubhouse will be outside in the weather for many years, so be sure to cover all exposed wood surfaces thoroughly with two coats of latex outdoor house paint. And try not to drip too much on each other!

Ace hardware is happy to provide these instructions. Use them as a guide to get started, and feel free to embellish them with any touches your carpentry skills permit. Just remember to be safe, have fun, and stop by the friendly hardware folks at Ace for all the tools, supplies and know-how you need to build the ultimate dream clubhouse!

Back to Steps 1 - 2

back to top

Check your state and local codes before starting any project. Follow all safety precautions. Information in this document has been furnished by the North American Retail Hardware Association (NRHA) and associated contributors. Every effort has been made to ensure accuracy and safety. Neither NRHA, any contributor nor the retailer can be held responsible for damages or injuries resulting from the use of the information in this document.