How do you make faux wood beams?
I learned how to build faux wood beams DIY when I was remodeling my kitchen. I wanted to create more open space to move and spread light. Older homes are often overbuilt when it comes to walls. I needed to bring this wall down and open it up but also be mindful that it was a load bearing wall. I decided to create a support beam built into the kitchen island.
Homemade faux wood beams
This created the problem of needing to cover the support framing and making it look nice. The only way that seemed to build faux wood beams DIY. Since then I have used fake wood beams as a decorative touch in other home rehabs.
What size should faux wood beams be?
I prefer 8 inches by 8 inches because that most accurately looks like a solid timber of wood. You can go for 6 inches by 6 inches if you have less space to build.
How to build fake wood beams DIY
Step 1: Measure
Measure the space of the structural beam that needs to be covered. You want to know how much space to cover and how much plywood you will need. The beams I was designing were 8 inches wide and 5.5 inches deep in a rectangular shape. This was the size I needed to cover the ugly structural framing.
There are 3 vertical columns that need to be covered that are 7 foot each. Then at the top there is a widthwise pieces that spans 13 feet.
Step 2: Calculate material needed to build faux wood beams DIY
Figure out how much wood you will need to complete the process. I prefer to calculate based on the dimensions of the proposed beams. The result was that I estimated I need 64 square feet of plywood. This broke down to 2 sheets of plywood needed rounding up to 3 for extras and mistakes. Below is my math.
Width of vertical beams
8″/12″ = .6666. .66666 x 7′ = 4.6 x 6 = 28 SqFt
Depth of vertical beams
5.5’/12″ = .4583. .4583 x 7′ = 3.2 x 4 = 12.8 SqFt
Width of top beam
8″/12″ = .6666. .6666 x 13′ = 8.6 x 2 = 17.33 SqFt
Depth of top beam
5.5”/12″. = .4583. .4583 x 13′ = 5.9 SqFt
Total square footage: 64 SqFt
1/4 inch 4’x8′ sheets needed = 3
Step 3: Make markings on the wood in preparation for cutting
Make measurements of the cuts on the plywood. I will start with the dimensions needed for the vertical columns. For the long pieces that are 7 feet tall you will obviously cut lengthwise on the 4×8 plywood. I needed 6 pieces that were 8 inch by 7 foot. I needed 4 pieces that are 5.5 inch by 7 foot.
For the top 13′ beam I needed two pieces that are 8 inches by 8 feet. To extend to 13 feet total I need two more pieces that are 8 inches by 5 feet. For the underside of the top beam I need a piece that is 79 inches by 5.5 inches and another that is 46. 5 inches by 5.5 inches.
These are all the pieces needed for my project. Your project may require more pieces and complexity depending on the dimensions of the house.
Step 4: Make cuts
Start making measured cuts on the plywood. I would recommend using a circular saw that has a cutting plate that can be adjusted with a bevel. This will allow you to cut at a 45 degree angle. To build faux wood beams DIY you will need the ends to be cut at a 45 so they will make a rectangle shape. The 45 degree ends will fit into each other and can then be glued and nailed together.
I would recommend cutting a few pieces for each column and then bring them into the house to see how they fit. There is no doubt this will be a process of trial and error and some pieces will have to be taken back out and recut. Once you have the first column cut and nailed together it gets easier.
Step 5: Assemble the beams
To build faux wood beams DIY start by building the 3 columns first and then end with the 13′ top beam. Make your measurements accordingly so the top beam lines up with the bottom 3 columns. Apply a bead of glue along the edge with the 45 degree cut and nail pieces together using a brad nails.
You can also nail the wooden boards into the framing that is being covered. Line up the edges as close as possible but if there is a small gap it can be filled with painters caulk later.
Step 6: Prepare for installation
In my project the top beam that runs along the ceiling is 13 feet long. It should run perpendicular to the columns. To complete this I need to have a 8 foot long piece and a 5 foot long piece blend together to look like one. This will have to be done on both sides of the top beam. There will be an underside of the beam made of a 79″ piece and a 45″ piece.
Step 7: Caulk the edges
All the pieces have now been in stalled now is the part where we caulk everything to make it pretty. I applied painters caulk to the gaps between the boards and to the nail holes. After the caulk dries sand the beams with an orbital sander to make everything smooth. The faux wood beams should look square and smooth.
Step 8: Staining is fun!
Now is the time to make the faux wood beams really look nice. We are ready for the staining process! To start drop a drop cloth under the area that you will be staining so you don’t ruin your floors. It is also a good idea to get a fan pointing out a window to create ventilation and suck fumes out. Stain has a pretty noxious smell and you don’t want to be breathing that in.
I chose to use a dark walnut stain that works really well for staining plywood. Plywood is not the highest quality wood compared to proper lumber. However the dark walnut is dark enough that it covers the imperfections but still shows off the grain of the wood. For higher quality wood you can use lighter stains that show off wood grain.
Step 9: Add sealer coat
We have now learned to build faux wood beams DIY! At this point you can choose to add a sealer coat to the stained wood to add some sheen. Since the beams are inside they don’t necessarily need a sealer coat. However a sealer coat can be a good idea if you have kids or pets.
How much does it cost to build faux wood beams DIY
| Material | 2 sheets 1/4 inch plywood | Stain | Wood Caulk | Sand paper | Total |
| Cost | $60 | $23 | $9 | $8 | $100 |
Best wood to build faux wood beams
I used regular 1/4 plywood and stained it to make it look nice. I have seen many faux beams for sale online made of fancy hardwood but this is not necessary. Using stain will make the quality of the wood less important. The 1/4 plywood can be cut into long strips that are glued and nailed together into a square shape. Cut the pieces at a 45 degree angle and they will lay against each other smoothly.
Are faux wood beams cheaper than wood?
Yes faux wood beams are made of plywood which is significantly cheaper than large pieces of lumber. Plywood costs $30 a sheet while a similar 8×8 post costs $71.
Are faux beams hard to install?
Building faux beams DIY can definitely take some carpentry skills. Installing pre built beams should be easy that anyone can do it.
Do faux beams add value?
Faux beams increase the aesthetics of the house and thus add value to the house. This is especially true if you build faux wood beams DIY, the value added will be higher than the cost.
More decorative beam ideas
Here a few more ideas to consider to customize your faux wood beam.
Add lighting, outlets or switches
I added an outlet and a 3 way switch for one of the main lights in the kitchen. Make sure the electrical work is added before the wood of the beams is installed. Be careful not to nail into the electrical wiring. Another option is adding a row of lights. This can really bring attention to the colors of the stained wood.
Rustic unstained
You can use wood that is aged or has some bark on it still to create a rustic cabin vibe. The wood would be unsanded and unstained to keep the look of the surface natural. The nails might be more visible with this approach and painters caulk wont be an option. The imperfections can add to the character of the space. This would fit in a outdoorsy space but wouldn’t fit in many other designs.
Add Some Hardware
If you really want to sell the faux beam as a real structural beam adding hardware can do the trick. Typically in real beams the hardware is installed where multiple beams unite. For example in my kitchen I have a T where one of the support pieces meets the top beam. This would be a great spot to add hardware.
Paint Beams
This is an area that really has limitless possibilities. A painted white beam along a wood panel ceiling would look really clean and nice. Or different beams can be painted any color really. Potentially a rainbow pattern or a gradient of colors could be funky and original.
Conclusion: Build faux wood beams DIY
It is easy to build faux wood beams DIY! I have seen faux wood beams selling online for exorbitant prices. It is completely unnecessary to buy a pre built faux wood beam when you can make one with plywood. Even if you use higher quality wood and put it together it will be much cheaper than buying a prebuilt faux beam.
More resources: https://www.minwax.com/en/wood-stain-color-guide/browse-color-stains