STARTER JIG

Abstract

A method and system for installing a first course of shakes or shingles on either a wall or a roof of a structure. The shake starter jig comprises an anchor leg with a first end and a second end, a suspension mechanism located adjacent the first end of the anchor leg to facilitate securing the shake starter jig to a desired surface, a ledger shelf supported adjacent the second end of the anchor leg, a ledger support rigidly affixed to a remote end of the ledger shelf, the second end of the anchor leg, the ledger shelf and the ledger support are all sized so as to facilitate receiving and accommodating a ledger board therebetween. The suspension mechanism is located a predefined distance away from the ledger shelf so as to facilitate spacing the ledger shelf a desired distance from a level line.

Description

FIELD OF INVENTION

The present invention relates to a novel wood and composite shake or shingle jig (with composite, meaning any concrete fiber, plastic, or any other artificial or synthetic material) for use in a siding or a roofing installation, which would be used in multiples and with a ledger board to facilitate proper installation of the first or bottom double course of horizontal shakes and shingles when commencing the process of either siding or roofing a desired structure, such as a house or a building.

BACKGROUND OF INVENTION

There are a variety of different techniques currently being utilized by carpenters and/or installers when installing the first or the starter course of shakes to a wall during siding of a house or building. One common technique is to cut the shakes at an equal height and then individually fasten shakes along a level horizontal chalk line, generally “snapped” from one vertical edge or corner of the house or the building to the opposite vertical edge or corner of the house or the building, at a predetermined height from the ground or the foundation. Such technique, if executed properly, can be quite accurate but is generally very tedious and time consuming.

While other methods and processes, which are known and utilized to assist with the installation of the first or the starter course of shakes to the side wall of a house or a building, have been the standard, none of these currently known methods offer the desired accuracy, ease of installation, and a reduction in the overall installation time. The present invention not only saves time and ensures installation accuracy, but it is also quite simple to use and thereby addresses a number of problems associated with the prior art methods and processes.

SUMMARY OF THE INVENTION

Wherefore, it is an object of the present invention to overcome the above noted drawbacks associated with prior known installation techniques and methods.

Another object of the present invention is to provide a shake and shingle starter jig that is relatively inexpensive to manufacture and is easy to utilize while, at the same time, provides an accurate and reliable system for installing wood or composite shakes and shingles to the side wall or roof of a house or building.

A further object of present invention is to provide a shake starter jig which is easily and accurately installed to a side wall or roof of a house or a building and can thereafter be easily removed therefrom following installation of the first or the starter course of shakes.

Another object of present invention is to facilitate adjustment of the relative position of the ledger shelf, for the first under laying course of starter shakes, and thereby provide the installer with the option of quickly and easily installing a drip course, i.e., a drip outer course of shakes. The drip outer course of shakes means an outer course of shakes overlies a base layer of shakes and prevents water from backing up against the building and the rear surface of the shakes.

Yet another object of the present invention is to substantially decrease the installation time of what is normally a tedious and time consuming process when installing shakes or shingles to the side wall or the roof of a house or a building, while still maintaining the desired installation accuracy.

The present invention relates to a shake starter jig for installing a starter course of shakes to a surface of a structure, the shake starter jig comprising: an anchor leg having a first end and a second end; a suspension mechanism being located adjacent the first end of the anchor leg to facilitate securing the shake starter jig to a desired surface; a ledger shelf being supported adjacent the second end of the anchor leg; a ledger support being rigidly affixed to a remote end of the ledger shelf; the second end of the anchor leg, the ledger shelf and the ledger support being sized to facilitate receiving and accommodating a ledger board therebetween; and the suspension mechanism being located a predefined distance from the ledger shelf to facilitate spacing the ledger shelf a desired distance from a level line to be applied to surface.

The present invention also relates to a method of installing a starter course of shakes on a surface of a structure utilizing at least first and second shake starter jigs, with each of the shake starter jigs comprising an anchor leg having a first end and a second end, a suspension mechanism located adjacent the first end of the anchor leg to facilitate securing the shake starter jig to a desired surface of a structure; a ledger shelf being supported adjacent the second end of the anchor leg; a ledger support being rigidly affixed to a remote end of the ledger shelf; the second end of the anchor leg, the ledger shelf and the ledger support being sized to facilitate receiving and accommodating a ledger board therebetween; and the suspension mechanism being located a predefined distance away from the ledger shelf to facilitate spacing the ledger shelf a desired distance from a level line, the method comprising the steps of: drawing a level line on the structure; affixing the first shake starter jig on the surface of the structure with the suspension mechanism is aligned with the level line; affixing the second shake starter jig on the surface of the structure, spaced from the first shake starter jig, with the suspension mechanism aligned with the level line; supporting a ledger board on a ledger shelves of the first and second shake starter jigs; supporting a plurality of shakes on a support surface of the ledger board; and affixing the plurality of shakes to the surface of the structure so as to form the a starter course of shakes.

When a drip course is desired, before the second course of shakes are aligned along the ledger board, each of the shake starter jigs and therewith the ledger board are adjusted downward, using calibrated measurements imprinted on the fastening leg; after the shake starter jigs are adjusted, they are resecured to the wall/roof and the ledger board is reinstalled; the shakes forming the drip course are now arranged on top surface of the shelf created by the ledger board, using proper gapping and spacing from under course of shakes; the shakes forming the drip course may now be properly secured to wall.

BRIEF DESCRIPTION OF DRAWINGS

The invention will now be described, by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a diagrammatic perspective view of the shake starter jig according to a first embodiment of the present invention;

FIG. 2A is a front elevational view of the shake starter jig according to FIG. 1;

FIG. 2B is a detailed front elevational view showing a variation of the upper portion of the shake starter jig according to the first embodiment;

FIG. 3A is a left side elevational view of the shake starter jig according to FIG. 1;

FIG. 3B is a left side elevational view of showing a variation of the upper portion of the ledger support according to the first embodiment;

FIG. 4A is a diagrammatic left side sectional view showing the shake starter jig attached to a side wall of a structure and supporting a ledger board with two overlapped layers of shakes supported on the ledger board;

FIG. 4B is a left side elevational view, showing engagement of the shake starter jig with two layers of shakes and ledger board;

FIG. 4C is a left-side view, showing an arrangement of two courses of shakes, one of which forms a drip outer course;

FIG. 5 diagrammatically shows a pair of spaced apart shake starter jigs with a ledger board being supported by and extending slightly beyond a pair of jigs, with a row of shakes or shingles, to be installed, resting on the top surface of the ledger board;

FIG. 6 diagrammatically shows a single one of two pairs shake starter jigs, each pair supporting a ledger board such that the ledger boards are horizontally aligned;

FIG. 7 is a diagrammatic perspective view of a second embodiment of the shake starter jig according to the present invention;

FIG. 8 is a front elevational view of the shake starter jig according to FIG. 7;

FIG. 9 is a left side elevational view of the shake starter jig according to FIG. 7;

FIG. 10A is a diagrammatic left side sectional view showing attachment of the shake starter jig of FIG. 7 to a side wall of a structure and supporting a ledger board thereon;

FIG. 10B is a left side elevational view of FIG. 10A supporting shakes for securing to a wall; and

FIG. 11 diagrammatically shows a pair of spaced apart shake starter jigs with a ledger board being supported by and extending slightly beyond the pair of starter jigs with a row of shakes or shingles, to be installed, resting on the top surface of the ledger board.

DETAILED DESCRIPTION OF THE INVENTION

The invention hereafter will be described in relation to the installation of shakes, however it is to be understood that the shake starter jig can be utilized in the installation of a number of different building elements such as shakes, shingles, clapboard or lap, for example. In addition, it is to be recognized that these building elements may be formed from a number of different materials such as wood, plastics, composites, etc. Further, although the invention herein is described in relation to the installation of siding to an exterior side wall of a structure, such as a house or a building, it is to be understood that the shake starter jig 2 can be used during the installation of a roofing material on a house or a building, for example.

Turning now to FIGS. 1-4B, a detailed description of the various components of the shake starter jig 2, according to the present invention, will now be provided. As shown in FIG. 1, the shake starter jig 2 comprises an elongate, unitary bent component or tool which does not include any moving parts. The shake starter jig 2 typically has a width of between ½ inch to 5 inches or so, and more preferably has a width of between 1 inch and 2 inches or so. In addition, the shake starter jig 2 has a thickness of between 1/32 to ⅛ inch, and more preferably a thickness of about 1/16 inch or so. The shake starter jig 2 typically has an overall length of between 8 inches to 40 inches or so, and more preferably a length of between 12 inches to 35 inches or so, and most preferably a length of about 30 inches or so.

The shake starter jig 2 comprises a generally elongated and planar anchor leg 8 which is, during use, typically vertically positioned and orientated, as shown in FIGS. 1, 2A and 3A. Like the shake starter jig 2, the anchor leg 8 has an overall length of between 8 inches to 40 inches or so, and more preferably a length of between 12 inches to 35 inches or so, and most preferably a length of about 30 inches or so. An upper section of a front face 35 of the anchor leg 8 is inscribed with a main position indicator 5 which is normally use during initial installation of the shake starter jig 2. The function and purpose of the main position indicator 5, which assists with properly positioning the shake starter jig 2 at a desired vertical position during the installation process of shakes/shingles to the side wall or roof of a house or building, will be discussed in further detail below. Typically, first and second adjustment markers 6 are marked or inscribed on the upper end or section of the front face 35 of the anchor leg 8, at a location slightly above the main position indicator 5, to assist with subsequent repositioning of the shake starter jig 2 when a drip course 17 is to be installed (see FIG. 4C), in order to provide additional water protection, and a further discussion concerning the same will follow below. A suspension mechanism, such as an opening, recess, aperture, anchor hole 7, is located adjacent the first longitudinal end of the anchor leg 8 vertically above and adjacent the first and second adjustment markers 6 and the main position indicator 5. The anchor hole 7 facilitates securing the shake starter jig 2 to a desired side wall or roof of a house or a building, at a desired location, once the shake starter jig 2 is properly aligned and oriented.

The lower second end or section of the anchor leg 8 terminates in a substantially right angle bend at a known and fixed distance, e.g., typically 24 inches, from the main position indicator 5. This bend of the anchor leg 8 forms a corresponding ledger shelf 3 which is provided for supporting a desired ledger board 9 in a substantially vertical orientation, as will be discussed below in further detail. The ledger shelf 3 extends from the front face 35 of the anchor leg 8 typically a distance or length of between ½ inch to 1 inch, and more preferably the ledger shelf 3 has a length of approximately 13/16 of an inch or so. An opposite end of the ledger shelf 3, remote from the anchor leg 8, terminates in a second substantially right angle bend which extends generally vertically upward and parallel to the anchor leg 8 so as to form a “J” shape shake starter jig 2, see FIGS. 3A and 3B for example. The upward bend forms a lateral ledger support 4 which assists with sandwiching and supporting the ledger board 9 in an essentially vertically upright orientation and position, as generally shown in FIGS. 4A, 4B, 5 and 6, on the ledger shelf 3 and between the second section of the anchor leg 8 and the ledger support 4.

FIG. 3B shows a slight variation of the shake starter jig 2 in which the ledger support 4 may extend vertically upward from the ledger shelf 3 but at an acute angle with respect to the ledger shelf 3, i.e., the ledger support 4 forms an acute angle therebetween which is less than 90 degrees and typically between 88 and 70 degrees, for example. According to this embodiment, the ledger support 4 extends away from ledger shelf 3 but slightly toward the anchor leg 8 and is thus configured so as to apply a clamping pressure against an exterior surface 20 of the ledger board 9, when accommodated between the second section of the ledger support 4 and the anchor leg 8, and thereby assist with retaining the ledger board 9 in engagement with the shake starter jig 2. In this manner, the ledger support 4 not only supports the ledger board 9 in a substantially vertically upright orientation and position, but also assist with clamping and retaining the ledger board 9 in this orientation and position.

A top free end 19 of the ledger support 4 bends slightly away from the anchor leg 8, e.g., by an angle of between 5 and 20 degrees or so, so as to facilitate receiving and insertion of the ledger board 9 between the ledger support 4 and the anchor leg 8. The bend of the top free end of the ledger support 4 enables the installer to easily and readily insert the leading end of the ledger board 9 between the second section of the anchor leg 8 and the ledger support 4.

As shown in FIG. 4A, the shake starter jig 2 is typically secured to an exterior sheathing 21 which forms an exterior side wall of a house or a building. The sheathing 21 is, in turn, secured to a frame 22 of the house or the building in a conventional manner. As is customary and well known in the art, the frame 22 is generally secured to a sill plate 23 which, in turn, is secured to the upper surface of the building foundation 13, in a conventional manner. As the above described as well as other similar types of construction techniques are conventional and well known in the art, a further detailed discussion concerning the same is not provided herein. The sheathing 21, which is fixed to the outwardly facing exterior surface of the frame 22, is shown in greater detail in FIG. 4B. As shown in that figure, the shake starter jig 2 is secured the sheathing 21 at a desired installed position prior to installing the first or the starter course of shakes 10 or 11 to the side wall or the roof of the house or the building.

Typically, a pair of spaced apart shake starter jigs 2 are used in combination with a relatively straight ledger board 9 which has a relatively easy workable length, e.g., each ledger board 9 typically has a length of between 1 feet and 16 feet, for example, and more preferably has a length of between 6 feet and 12 feet or so. Each of the ledger boards 9 is ripped or sawn to typically have equal widths W and thicknesses T with one another. The ledger boards 9 typically have a thickness of preferably between ½ inch to 1 inch and more preferably % of an inch. If more than one ledger board 9 is to be used during the installation process of the first or the starter course (see FIG. 6), then each ledger board 9 should have the same width W (see FIG. 4B). The width W of the ledger boards 9 is preferably between 2½ inches and 5 inches, and more preferably the width of the ledger board 9 is between 2¾ and 4½ inches.

Use of Shake Starter Jig

With reference to the FIGS. 1-6, installation and use of the shake starter jig 2, according to the present invention, will now be described. As is conventional in the art, the first step is to determine the desired location for placement of a level line on the surface of the side wall, e.g., the exterior sheathing 21, of the house or the building. This is achieved by first determining the distance D, from the top of the foundation 13, at which the level (chalk) line 15 is to be “snapped” in a conventional manner. In order to make this determination, the width W of the ledger boards 9 is added to the desired amount of overhang O, if any, from the top of the foundation 13 to a bottom butt edge 16 of the under course of shakes 11 of the starter course.

Although the method of installing the first or the starter course with the shake starter jig 2 can be employed using ledger boards, overhangs and shakes of virtually any size, for the sake of illustration only, in the following description the width W of the ledger board is assumed to be 5 inches while the desired amount of overhang O is assumed to be 1 inch. With these assumed dimensions, the sum of width W of the ledger board 9, which is 5 inches, plus the desired overhang O, which is 1 inch, equals a total of 6 inches. Now, subtracting this amount from the overall working length of the starter jig 2 which is 28 inch (measured from the main position indicator 5 to a bottom of the ledger shelf 3) provides a length of 22 inches, namely, 5 inches+1 inch=6 inches and 28 inches−6 inches=22 inches). The installer will then mark the sheathing 21, at a plurality of spaced apart locations around the perimeter of the house or the building, at a distance D (see FIG. 5), which is located 22 inches above the top portion of the foundation 13 and this is the location where the level (chalk) line 15 is to be “snapped.” A conventional chalk line is then aligned with at least a pair of the various spaced apart markings on the sheathing 21 and the chalk line is then “snapped”, in a conventional manner, so as to provide a level (chalk) line 15 on the exterior surface of the sheathing 21. This process is repeated, as necessary, around the entire perimeter of the house or the building where the shakes or shingles are to be installed.

Thereafter, the first shake starter jig 2 is located a few inches inwardly from one vertical edge or corner of the house or the building, such that the main position indicator 5, provided on the upper section of the anchor leg 8, is precisely aligned with the level (chalk) line 15. A conventional screw or a nail 14 is then secured through the anchor hole 7 (FIG. 4A) to the side wall of the house or the building in order to secure the first shake starter jig 2 thereto. Next, at least a second shake starter jig 2′, and possibly additional shake starter jigs 2′, are suitably positioned and secured to the side wall of the house or the building in a similar fashion at spaced intervals from one another. The interval spacing of the first and the second shake starter jigs 2, 2′ is generally between 3 to 12 inches less than the overall length of the ledger board 9 to be supported by the pair of shake starter jigs 2, 2′. Following such installation, the shake starter jigs 2, 2′ are then positioned such that the ledger shelves 3, of the first and the second shake starter jigs 2, 2′, are thus aligned with one another and thereby form a hanging or suspended support system which define a substantially level horizontal support surface for supporting the ledger boards 9 in a generally end to end orientation, as shown in FIG. 6. Thereafter, a ledger board 9 is inserted into and received between the anchor legs 8 and the ledger supports 4, of the pair of spaced apart shake starter jigs 2, 2′ until the ledger board 9 is fully seated and abuts against and is supported on the ledger shelves 3 of the pair of shake starter jigs 2, 2′. Another pair of the shake starter jigs 2, 2′ can be similarly attached to the sheathing 21 and a second ledger board 9 can be installed closely adjacent the first ledger board 9 and thereby provide a longer, substantially continuous, surface for supporting and accommodating the desired shakes or shingles to be installed.

As shown in FIG. 4B, the ledger board 9 is vertically supported by the ledger shelves 3, of the first and second shake starter jigs 2, 2′, and laterally secured by the respective anchor legs 8 and the ledger supports 4 such that the width W of the ledger boards 9 is aligned at least substantially vertically. A vertically upper surface of the ledger board 9, once supported by the pair of shake starter jigs 2 as shown in FIGS. 4B, 5 and 6, thereby forms a shake support surface 27 that is normal to the anchor leg 8 and the surface of the side wall. When a plurality of sequentially arranged shake starter jigs 2 and ledger boards 9, and therefore shake starter jigs 2, are utilized for installing the first or the starter course of shakes (FIG. 6), the longitudinal ends of the ledger boards 9 are located closely adjacent one another such that the shake support surfaces 27 thereof form a substantially continuous shake support surface 27 that does not have any large gaps or opening located between the sequentially arranged, end to end, ledger boards 9. This facilitates placement of the under course of shakes 11 regardless of the width of the shakes.

Next, the installer then places the desired shakes or shingles on the shake support surface 27 such that the thicker butt edges 16 of the shakes or shingles engage with and rest upon the shake support surface 27 while the opposite end of the shakes extend parallel and along the side wall of the house or the building. The installer can then rearrange the initially placed shakes, in any desired orientation while the shakes are loosely supported on the shake support surface 27, to provide desired arrangement, spacing and aesthetic appearance for the shakes following completion of the installation process. Once the installer determines that the desired shake arrangement is achieved, the installer then permanently fastens the under course of shakes 11 to side wall in a conventional manner by using shingle or shake nails or other suitable fasteners (i.e., either manually or via use of an automated tool).

Thereafter, the installer may then continue by installing an outer course of shakes 10, directly over the under course of shakes 11, without adjusting the position of any of the shake starter jigs 2. If this is to occur, the installer then places the thicker butt edges 16 of the outer course of shakes 10 on the shake support surface 27 of the ledger boards 9, in the manner discussed above with respect to the under course of shakes 11, such that the outer course of shakes 10 overlaps the under course of shakes 11. If desired or necessary, the installer can then rearrange the shakes prior to permanently fastening the outer course of shakes 10 to both the under course of shakes 11 and the side wall of the house or the building in a conventional manner, and thereby complete the starter course of shakes for the house or building.

Alternatively, the installer may desire to create a drip outer course of shakes 10′, which assists with the shedding water from the side wall of the house or the building. In the event that a drip outer course of shakes 10′ is desired, then following installation of the under course of shakes 11, each one of the shake starter jigs 2 must be adjusted by first removing the ledger boards 9. Next, each one of the shake starter jigs 2 is vertically lowered a small distance, i.e., the desired amount of the drip edge for the drip outer course of shakes 10′. This can be accomplished by a completely removing the screws or the nails 14, from the anchor holes 7 of each one of the shake starter jigs 2, and, thereafter, repositioning the shake starter jig 2 at a desired vertically lower distance such that a selected one of the adjustment scribes 6, 6′ is now aligned with the level (chalk) line 15. The desired adjustment scribe 6, 6′ (FIG. 2B) depends on the amount of the desired vertical drop between the butt edge 16 of the under course of shakes 11 and the butt edge 16 for the drip outer course of shakes 10′. Two desired amounts of vertical lowering, in order to create the drip course 17, is indicated on the adjustment scribes 6, 6′ located just above main position indicator 5. For example, the two adjustment scribes 6, 6′ each generally have a dimension ranging from about ¼ to 1 inch with either ¼, ⅜, ½ or ⅝ of an inch typically being a preferred amount of vertical drop between the butt edge 16 of the outer course of shakes 10 and the butt edge 16 of the drip outer course of shakes 10′.

Once all of the shake starter jigs 2 are suitably repositioned, then the ledger boards 9 are then reinserted into the shake starter jigs 2, as described above. It is to be appreciated that it is possible to reposition the shake starter jigs 2 without having to remove the ledger boards 9, since this would generally increase the overall speed of adjusting the position of the shake starter jigs 2, 2′. The installer then completes the installation process of the shakes for the drip outer course of shakes 10′ by placing the butt edges of the drip course 17 on the shake support surface 27 of the ledger boards 9, such that the outer course of shakes 10′ overlaps the under course of shakes 11 and, if necessary or desired, rearranges the initially placed shakes in a desired orientation while they are supported on the shake support surface 27 so as to provide desired arrangement, spacing and appearance for the shakes following installation. Once the desired arrangement is achieved, the installer then permanently fastens the drip outer course of shakes 10′ to the under course of shakes 11 and the side wall in a conventional manner, by using shingle or shake nails or other suitable fasteners, and thereby creating a drip course 17 which assists with shedding of water (see FIG. 4C).

Finally, the installer then removes the ledger boards 9 from the pair of spaced apart shake starter jigs 2 and, thereafter, each one of shake starter jigs 2 is removed by removing the associated screw or the nail 14, used to secure the shake starter jig 2 to wall. Thereafter, each one of the shake starter jigs 2 is then gently and gradually slid, in a vertically downward direction, so that the anchor leg 8 is totally extracted from its installed position located behind the installed starter course of shakes 11, 10, 10′ or 17.

A slight variation of the shake starter jig 2 is shown in FIG. 2B and this variation also includes an anchor leg 8 which has an upper section that includes both the main position indicator 5 as well as a pair of adjustment markers 6 which form a pair of adjusted positions for the shake starter jig 2. According to this embodiment, the main position indicator 5 and the pair of adjustment markers 6 are generally used for the same purposes discussed above. Since this variation is quite similar to the first embodiment, only the difference between this variation and the previous embodiment will be discussed in detail.

As shown in FIG. 2B, instead of having a single circular anchor hole 7, the anchor hole comprises an aperture 30 having three cup shaped jig supports 31, 32, 33 for supporting the starter jig 2 at a different distance from the bottom of the ledger shelf 3. The lowermost jig support 31 is associated with the main position indicator and is located a desired distance, e.g., 28 inches for example, from the bottom of the ledger shelf 3. The middle jig support 32 is associated with a first adjustment marker 6, e.g., ¼ inch adjustment marker, and is located ¼ inch above the lowermost jig support 31. An uppermost jig support 33 is associated with a second adjustment marker 6, e.g., ½ inch adjustment marker, and is located ½ inch above the lowermost jig support 31.

The anchor hole 7, comprising an enlarged recess or aperture 30 having the three selectable jig supports 31, 32, 33, is beneficial when repositioning of the shake starter jig 2 is desired in order to install the drip outer course of shakes 10′, as discussed above. According to this variation, it is not necessary to completely remove the associated screw or the nail 14 in order to facilitate repositioning of the shake starter jig 2. That is, the associated screw or the nail 14 is only partially withdrawn or removed from the side wall so that the associated shake starter jig 2 or 2′ can thereafter be freely moved vertically downward. Once the screw or the nail 14 is sufficiently partially removed or withdrawn, each one of the shake starter jigs 2, 2′ can then be repositioned, i.e., the shake starter jigs 2 can be moved from being supported by the lowermost jig support 31 to one of the other jig supports 32 or 33 depending upon the desired amount of the drip edge. In this manner the shake starter jig 2 can be repositioned without the need to fully remove the screw or nail 14 and then reinsert a screw or nail 14 in the associated shake starter jig 2 at a different location. Moreover, it is to be appreciated that the ledger board(s) 9 may, or may not, have to be removed from the shake starter jigs 2, 2′ during such repositioning.

With reference now to FIGS. 7 through 11, a second embodiment of the present invention will now be discussed. As this embodiment is very similar to the first embodiment, only the differences between the second embodiment and the first embodiment will be discussed.

As shown in FIGS. 7-9, the second embodiment of the shake starter jig 2 also comprises an elongate, unitary bent component or tool which does not include any moving parts and comprises a generally elongated and planar anchor leg 8 which is typically vertically positioned and orientated, as shown in FIGS. 10A and 10B, during use. As with the first embodiment, the anchor leg 8 has an overall length of typically between 12 inches to 36 inches or so, typically about 28 inches or so and a front face 35, of an upper first section 8 of the anchor leg, is inscribed with a main position indicator 5 which is normally used during initial installation of the shake starter jig 2. As with the prior embodiment, the main position indicator 5 assists with properly positioning the shake starter jig 2 during the installation process of shakes/shingles on the side wall or roof of a house or a building. Typically, first and second adjustment markers 6 are also marked or inscribed on the upper portion of the front face 35 of the anchor leg 8, slightly above the main position indicator 5, to assist with repositioning of the shake starter jig 2 when a drip course 17 is to be installed (see FIG. 4C), in order to provide additional water protection.

One difference with respect to the anchor leg 8 is that the anchor leg 8, according to the second embodiment, comprises three sections, namely, the first section 8′ which supports the main position indicator 5 and the first and second adjustment markers 6, a second section 8″ which is integral with the ledger shelf 3, and an intermediate section 8″ which couples were interconnects the first section 8′ with the second section 8″. As can be seen in FIGS. 7 and 8, the intermediate section 8″ forms an angle of between approximately 100 and 135 degrees, more preferably an angle of about 115° or so, with the front surface 35 of the first section 8′, while the intermediate section 8″ forms an angle of between approximately 100 and 135 degrees, more preferably an angle of about 115° or so, with the second section 8′″ of the anchor leg 8 to thereby form a stepped out section 18 for the shake starter jig 2, the purpose of which will be become readily apparent in view of the following description.

A suspension mechanism, such as an anchor hole 7, is located within the first section 8′ of the anchor leg 8, vertically above and adjacent the first and second adjustment markers 6 and the main position indicator 5. It is to be appreciated that the precise location of the anchor hole 7 can vary depending upon the particular application without departing from the spirit and scope of the present invention. The anchor hole 7 facilitates securing the shake starter jig 2 to a desired side wall or roof of a house or a building, at a desired location, once the shake starter jig 2 is properly aligned and oriented.

As with the previous embodiment, the lower second end of the anchor leg 8 terminates in a substantially right angle bend at a desired distance, e.g., typically 28 inches, from the main position indicator 5. This bend of the anchor leg 8 also forms a corresponding ledger shelf 3 for supporting a desired ledger board 9 in a substantially vertical orientation. However, due to the stepped out section 18 of the anchor leg 8, according to this embodiment, the ledger shelf 3 is bent in an opposite direction, e.g., toward the sheath engaging second surface 36 of the shake starter jig 2. The ledger shelf 3 extends from the second face 36 of the anchor leg 8 typically a length of between ½ inch to 1 inch, and more preferably the ledger shelf 3 has a length of approximately 13/16 of an inch, or so.

An opposite end of the ledger shelf 3, remote from the anchor leg 8, also terminates in another right angle bend which extends generally vertically upward and parallel to the second section 8′″ of the anchor leg 8 so as to form a “J” shape shake starter jig 2, as generally shown in FIGS. 7, 10A and 10B. The upward bend comprises a lateral ledger support 4 which assists with supporting the ledger board 9 in an essentially vertically upright orientation and position, as generally shown in FIGS. 10A, 10B and 11. Preferably, both the first section 8′ of the anchor leg 8 and the lateral ledger support 4 extend parallel to one another. More preferably, both the first section 8′ of the anchor leg 8 and the lateral ledger support 4 extend parallel to one another and are coplanar with one another.

According to this embodiment of the shake starter jig 2, the ledger support 4 extends vertically upward from the ledger shelf 3 at generally a right angle or a slight acute or obtuse angle with respect to the ledger shelf 3, i.e., the ledger support 4 forms an angle of 90±5 degrees, for example. As a result of such arrangement, the ledger support 4 extends away from ledger shelf 3 but gradually toward the second section 8′″ of the anchor leg 8 is thus arranged so as to apply slight pressure against an exterior surface 20 of the ledger board 9, when accommodated between the ledger support 4 and the anchor leg 8, and thereby retain the ledger board 9 in engagement with the shake starter jig 2. In this manner, the ledger support 4 not only supports the ledger board 9 in a substantially vertically upright orientation and position but also assist with clamping and retaining the ledger board 9 in this position and orientation.

The top free end of the ledger support 4 typically has a length which is greater than the width of the ledger board 9 to be supported thereby, e.g., the ledger support has a length of between about 2 to about 7 inches and more preferably about 5 inches. That is, as can be seen in FIGS. 10A and 10B, the free end of the ledger board is sufficiently long so as to overlap a portion of the exterior sheathing 21 which forms the exterior side wall of the house or the building, and thereby ensures that the ledger board 9 is correctly located for receiving and retaining a plurality of shakes or shingles to be applied to the exterior sheathing 21, as generally shown in FIGS. 10A, 10B and 11. That is, the top free end of the ledger support 4 ensures that the support surface 27 of the ledger board 9 is properly position for supporting at least two overlapped rows of shakes, e.g., the under and the outer course of shakes 10, 11.

Similar to the previous embodiment, as shown in FIG. 11, a pair of spaced apart shake starter jigs 2 are used in combination with one or more substantially straight ledger boards 9 which have relatively easy workable lengths. After snapping a level (chalk) line 15 in a conventional manner, the first shake starter jig 2 is located a few inches inwardly from one vertical edge or corner of the house or the building, so that the main position indicator 5, provided on the first section 8′ of the anchor leg 8, is precisely aligned with the level (chalk) line 15. A screw or a nail 14 is then secured to the side wall through the anchor hole 7 (FIG. 10A) in order to secure the first shake starter jig 2 to the side wall of the house or the building.

Thereafter, at least a second shake starter jig 2, and possibly additional shake starter jigs 2′, are positioned and secured to the side wall of the house or the building in a similar fashion at spaced intervals from one another. The interval spacing of the first and the second shake starter jigs 2, 2′ is generally between 3 to 12 inches less than the overall length of the ledger board 9 to be supported by the pair of shake starter jigs 2, 2′.

Following such installation, the shake starter jigs 2, 2′ are then positioned such that the ledger shelves 3, of the first and the second shake starter jigs 2, 2′, are thus aligned with one another and thereby form a hanging or suspended support system which defines a substantially level horizontal support surface for supporting the ledger boards 9 in a generally end to end orientation, as shown in FIG. 11. Thereafter, a ledger board 9 is inserted into and received between the third section 8′ of the anchor legs 8 and the ledger supports 4, of the pair of spaced apart shake starter jigs 2, 2′ until the ledger board 9 is fully seated and abuts against and is supported on the ledger shelves 3 of the pair of shake starter jigs 2, 2′. Another pair of the shake starter jigs 2, 2′ can be similarly attached to the sheathing 21 and a second ledger board 9 can be installed closely adjacent the first ledger board 9 and thereby provide a longer, substantially continuous, surface for supporting and accommodating the desired shakes or shingles to be installed.

Next, the installer then places the desired shakes on the shake support surface 27 such that the thicker butt edges 16 of the shakes engage with the shake support surface 27 while the opposite end of the shakes extend parallel and along the surface of the house or building. As with the previous embodiment, the installer can then rearrange the initially placed shakes in any desired position and/or orientation while the shakes are loosely supported on the shake support surface 27 to provide desired arrangement, spacing and aesthetic appearance for the shakes following completion of the installation process. Once the installer determines that the desired shake arrangement is achieved, the installer then permanently fastens the under course of shakes 11 to side wall in a conventional manner, as discussed above.

Thereafter, the installer may then continue by installing an outer course of shakes 10, directly over the under course of shakes 11, without adjusting the position of any of the shake starter jigs 2 or, as described above, or create a drip outer course of shakes 10′ which assists with the shedding of water from the side of the building by slightly lowering both of the shake starter jigs 2. In the event that a drip outer course of shakes 10′ is desired, then following installation of the under course of shakes 11, each one of the shake starter jigs 2 must be readjusted, as described above, by either completely removing the screws or the nails 14, from the anchor holes 7 of each one of the shake starter jigs 2, and, thereafter, repositioning the shake starter jig 2 at a desired vertically lower distance such that a selected one of the adjustment scribes 6, 6′ is now aligned with the level (chalk) line 15 or, repositioning the screw or the nail 14 in another one of the three selectable jig supports 31, 32, 33.

Once all of the shake starter jigs 2 are suitably repositioned, then the ledger boards 9 are then reinserted into the shake starter jigs 2, as described above, if the ledger board 9 was removed. The installer then completes the installation process of the shakes for the drip outer course of shakes 10′ by placing the butt edges of the drip course 17 on the shake support surface 27 of the ledger boards 9, such that the outer course of shakes 10′ overlaps the under course of shakes 11 and, if necessary or desired, rearranges the initially placed shakes in a desired orientation while they are supported on the shake support surface 27 so as to provide desired arrangement, spacing and appearance for the shakes following installation. Once the desired arrangement is achieved, the installer then permanently fastens the drip outer course of shakes 10′ to the under course of shakes 11 and the side wall in a conventional manner, as discussed above.

Finally, the installer then removes the ledger boards 9 from the pair of spaced apart shake starter jigs 2 and, thereafter, removes each one of shake starter jigs 2 by removing the associated screw or the nail 14, used to secure the shake starter jig 2 to wall. Thereafter, each one of the shake starter jigs 2 is then gently and gradually slid, slightly in a vertically downward direction, so that top free end of the ledger support 4 is extracted from its installed position located behind the installed starter course of shakes 11, 10, 10′ or 17. It is to be appreciated that the second embodiment of the shake starter jig 2 is much easier to remove, following installation of the installed starter course of shakes 11, 10, 10′ or 17, since only a small portion of the shake starter jig 2 is located behind the installed starter course of shakes 11, 10, 10′ or 17.

This above described installation process works similarly for the installation of both wood and composite shakes and shingles and is equally applicable for roofing applications thereby making a difficult installation job much easier, faster and more accurate. It is to be appreciated that the shake starter jigs 2 may also be utilized during installation of slate or a roof as well.

Preferably, the shake starter jig 2 is manufactured from resilient material such as spring steel, which provides increased resistance to bending and fatigue. It is also appreciated, however, that the shake starter jig 2 alternatively can be manufactured from a variety of materials other than spring steel (e.g., plastic, composites, etc.). The important aspect for the material that is used to manufacture the shake starter jig 2 is that such material be sufficiently rigid and durable to facilitate support and retention of the ledger board 9 and the desired shakes under a modest load.

It is to be appreciated that the ledger board 9 can be manufactured from a variety of other materials, such as wood, plastic, metal, etc. In the embodiment shown in FIGS. 4A-4B, 5 and 6 and 10A, 10B and 11, the ledger board 9 is generally a wooden board or plank.

Since certain changes may be made in the above described shake starter jig and installation method, without departing from the spirit and scope of the invention herein involved, it is intended that all of the subject matter of the above description or shown in the accompanying drawings, shall be interpreted merely as examples illustrating the inventive concept herein, and shall not be construed as limiting the invention.

Claims

1. A shake starter jig for installing a starter course of shakes to a surface of a structure, the shake starter jig comprising:

an anchor leg having a first end and a second end;

a suspension mechanism being located adjacent the first end of the anchor leg to facilitate securing the shake starter jig to a desired surface;

a ledger shelf being supported adjacent the second end of the anchor leg;

a ledger support being rigidly affixed to a remote end of the ledger shelf;

the second end of the anchor leg, the ledger shelf and the ledger support being sized to facilitate receiving and accommodating a ledger board therebetween; and

the suspension mechanism being located a predefined distance from the ledger shelf to facilitate spacing the ledger shelf a desired distance from a level line to be applied to surface.

2. The shake starter jig for installing a starter course according to claim 1, wherein a main position indicator is located adjacent the suspension mechanism to assist with positioning the shake starter jig on the surface of the structure.

3. The shake starter jig for installing a starter course according to claim 2, wherein at least one adjustment marker is provided adjacent the suspension mechanism to assist with repositioning of the shake starter jig, relative to a level line, when a drip course is to be installed on the structure.

4. The shake starter jig for installing a starter course according to claim 1, wherein a plurality of spaced apart adjustment markers are provided, adjacent the suspension mechanism, to assist with repositioning of the shake starter jig, relative to a level line, when a drip course is to be installed on the structure.

5. The shake starter jig for installing a starter course according to claim 1, wherein the suspension mechanism is an aperture having at least one support position for supporting the shake starter jig.

6. The shake starter jig for installing a starter course according to claim 5, wherein the aperture has a plurality of support positions for supporting the shake starter jig.

7. The shake starter jig for installing a starter course according to claim 1, wherein, when the ledger board is received by the second end of the anchor leg, the ledger shelf and the ledger support, a longitudinal surface of the ledger board lies substantially normal to the anchor leg and forms a shake support surface for supporting a plurality of shakes during installation of the starter course of shakes to the surface of the structure.

8. The shake starter jig for installing a starter course according to claim 1, wherein the shake starter jig is manufactured from resilient material.

9. The shake starter jig for installing a starter course according to claim 8, wherein the resilient material is one of spring steel, a plastic and a composite.

10. The shake starter jig for installing a starter course according to claim 8, wherein the shake starter jig has a width of between ½ inch to 5 inches, a thickness of between 1/32 to ⅛ inch, and length of between 8 inches to 30 inches.

11. The shake starter jig for installing a starter course according to claim 1, wherein the anchor leg is substantially planar.

12. The shake starter jig for installing a starter course according to claim 1, wherein the anchor leg comprises a first section, a second section and an intermediate section, the intermediate section forms an angle of between 100 and 135 degrees, and the intermediate section forms an angle of between 100 and 135 degrees with the second section of the anchor leg and thereby forms a stepped out section for the shake starter jig.

13. The shake starter jig for installing a starter course according to claim 1, wherein the ledger shelf is bent away from a sheath engaging second surface of the shake starter jig and has a length of between ½ inch to 1 inch.

14. The shake starter jig for installing a starter course according to claim 13, wherein the ledger support has a length of between 2 and 7 inches.

15. The shake starter jig for installing a starter course according to claim 1, wherein the ledger shelf is bent toward a sheath engaging second surface of the shake starter jig and has a length of between ½ inch to 1 inch.

16. The shake starter jig for installing a starter course according to claim 15, wherein a free end of the ledger board is sufficiently long so as to overlap a portion of an exterior side wall of the building, and ensures proper positioning of the ledger board for receiving and retaining a plurality of shakes to be applied.

17. The shake starter jig for installing a starter course according to claim 16, wherein the ledger support has a length of between 2 and 7 inches.

18. The shake starter jig for installing a starter course according to claim 13, wherein a free end of the ledger support bends slightly away from the anchor leg so as to facilitate receiving a ledger board between the ledger support and the anchor leg.

19. A shake starter jig for installing a starter course of shakes to a surface, the shake starter jig comprising:

an anchor leg having a top end and a lower end, the top end of the anchor leg having at least one marking thereon which is located at a specified distance from the lower end of the anchor leg,

an aperture being located adjacent the top end of the anchor leg for securing the shake starter jig to a desired surface;

a ledger shelf being rigidly fixed to the lower end of the anchor leg, the ledger shelf extending normal to the anchor leg such that the ledger shelf is at least substantially perpendicular to the surface of the structure; and

a ledger support being rigidly fixed to a remote end of the ledger shelf which is remote from the anchor leg, the ledger support forming an angle with the ledger shelf, the anchor leg, the ledger shelf and the ledger support supporting a ledger board such that one surface of the ledger board is at least substantially normal to the surface of the structure when the shake starter jig is secured to the surface of the structure, the surface of the ledger board forms a support surface which supports a plurality of shakes in a set position for installing the starter course of shakes on the surface of the structure.

20. A method of installing a starter course of shakes on a surface of a structure utilizing at least first and second shake starter jigs, with each of the shake starter jigs comprising an anchor leg having a first end and a second end, a suspension mechanism located adjacent the first end of the anchor leg to facilitate securing the shake starter jig to a desired surface of a structure; a ledger shelf being supported adjacent the second end of the anchor leg; a ledger support being rigidly affixed to a remote end of the ledger shelf; the second end of the anchor leg, the ledger shelf and the ledger support being sized to facilitate receiving and accommodating a ledger board therebetween; and the suspension mechanism being located a predefined distance away from the ledger shelf to facilitate spacing the ledger shelf a desired distance from a level line, the method comprising the steps of:

drawing a level line on the structure;

affixing the first shake starter jig on the surface of the structure with the suspension mechanism is aligned with the level line;

affixing the second shake starter jig on the surface of the structure, spaced from the first shake starter jig, with the suspension mechanism aligned with the level line;

supporting a ledger board on a ledger shelves of the first and second shake starter jigs;

supporting a plurality of shakes on a support surface of the ledger board; and

affixing the plurality of shakes to the surface of the structure so as to form the a starter course of shakes.