Sessile Oak
Sessile Oak workshop Intricate wooden carving

Case Study:
Larch Cottage Garden Theatre Stage

A look at how Sessile Oak's innovative Garden Theatre Stage at Larch Cottage Nurseries, runner-up Carpenters Fellowship Contemporary Oak Frame of the Year Award 2026, was designed and built.

Sorting and grading delivered timbers for use

Design

Background

We were approached by Larch Cottage Nurseries, for whom we had built two oak frames previously: a three-storey extension and a road-front store. This new commission was to design and build a theatre stage frame to mark the garden centre’s 40th anniversary and provide a venue for regular concerts and performances.

An initial site visit determined a footprint of 5m width x 4m depth and maximum height of 3.8m to work within. As ideas developed, so emerged a brief that the stage back should be 'masculine' whilst the stage front 'feminine', with a unique architectural theme in keeping with the naturally curved shapes of the surrounding trees, shrubs, lawns and paths.

The Frame Design Evolves

Early transverse design options It was clear right away that the limited dimensions, as well as the aesthetic brief, demanded as slim a structure as possible around the open stage front to maximise performers’ visibility. We produced a number of initial concept designs ranging from simple collared truss frames to a semi-ovoid gridshell, from which a frame featuring extensive use of large curves within a fairly conventional pitched outline was selected.

Second longitudinal design option

The design was refined over many cups of tea, excellent cake, much head scratching and plotting on graph paper with a pair of compasses. It would incorporate just over half a perfect circle formed by a pair of arch braces and collar as the ‘feminine’ stage front, contrasting with ‘masculine’ gothic arches in the stage back to create a hint of a Tolkienesque 'elvish' theme.

Eighth transverse design version

A frontal canopy reaching out to a point at its apex, with additional wind braces placed to draw the eye upward and outwards from the curves below to encourage the illusion of a sharper peak, was balanced at the back by a pair of thinner crossing curved struts within the diamond atop the arches to be glazed with Dalle de verre.

Carpentry

In the Workshop

Sorting and grading delivered timbers for use

The timbers for the arch braces were something of a challenge to source since their deflection had to be constant Cutting the curves to shape to a maximum point of 450mm at mid over a length of 3.2m - much greater than usual for braces and the like. Happily, as with a previous similarly challenging order, Vastern Timber came up with the goods. Upon delivery to our workshop at Sunnymede Barn, we set about matching contiguous faces and marking lines to achieve as close to symmetry of grain and shape as possible, which were then cut with our modified Westmac Jonsered 630 chainsaw. It was vital that the deflection of the curves’ grain and cuts together matched the design in order for them to work both structurally and visually.

Stage back frame in the workshop

The stage back chords were laid out and jointed with their arches, which were already cut and shaved to their finished curves. Where pieces lapped over one another in the centre, the draw of their pegs was lessened in favour of angled dovetail pegging. Shaping and jointing the front frame The curves of the stage front, however, were roughed out to around 50mm from their anticipated finished shape, ready for final marking when all jointed in. Once jointed and podgered, an old roofing batten with a pencil hole in one end was fixed 750mm Purlins and wind braces above the mid point of the floor to plot approximately three fifths of a perfect circle around the arc braces and collar, which were then removed and recut to their lines before reassembly for final shaving.

Shaping and jointing the side frame

The side and roof timbers were shaped very much as standard with the same precise attention to proportion and symmetry. The minimal sections of the principal rafters called for closer than usual tolerances for the socketed laps of the purlins and wind brace housings over and around the recessed arch brace and collar joints of the front frame, to retain as much residual section throughout as possible.

Cistercian numbers In a departure from the usual Roman carpenters’ marks, a variation on Cistercian numbering identified pieces and their positions to follow the ethereal theme.

On Site

The completed frame was delivered and erected in glorious sunshine on the 19th and 20th June 2025, with the client fitting the common rafters, Rosemary clay tile roof, lime rendered external Marmox wall panels and oak floor over the following late summer and autumn. The summer solstice of 2026 saw its well attended inaugural concert, raising money for local charities.

Roof structure of the finished frame
Sorting and grading delivered timbers for use

Carpenters Fellowship - Frame 2026

We travelled to the Carpenters Fellowship annual three-day gathering, this year at The Earth Trust near Oxford. We were delighted to be named runner-up in the Contemporary class of the Oak Frame of the Year Awards for the theatre stage, and to be featured in the forthcoming edition of The Mortice and Tenon magazine.

Other Oak Frames at Larch Cottage

Three Storey Extension

Larch Cottage Nurseries Three Storey Extension

We designed and built the three-storey extension at Larch Cottage Nurseries more than a decade ago, comprising a massive 16.2 tonnes of structural oak, all crafted by hand using traditional carpentry tools.

Larch Cottage Nurseries Three Storey Extension

Open-sided Store

Garden Centre Open-sided Store

We returned to design and build a green oak framed open-sided storage shed at roadside.

Garden Centre Open-sided Store

Environmentally Friendly

Oak tree

Our timbers are from sustainably managed and certified woodlands, sourced through well-established and reputable suppliers. This is essential for the continuing stewardship and survival of oak and mixed broadleaved woodlands, as well as the preservation of their habitats and wildlife.

Environment
Environmental Policy

Oak Frames in the Workshop

Larch Cottage front frame in the workshop

Our Sunnymede Barn workshop has hosted to more than fifty oak frame projects since it was built and can enclose structures of a moderate size.

Making a large oak truss in the yard

Some parts of large projects too big to fit in the workshop are still made outdoors in the elements.

Oak Frame Carpentry
Oak Frame Carpentry

Tools of the Trade

Large framing chisels

A brief look at some traditional carpentry hand tools we use in our workshop.

Carpentry Tools
Carpentry Hand Tools

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