How To: Install Fypon Beam Top and End Caps
Complete your Fypon woodgrain beam truss system or other beam project with our beam top and end caps.
Proper installation is key to achieving the desired look, so be sure to follow these step-by-step instructions and watch our accompanying how-to video to correctly install every time. You can also download a print-friendly version of these instructions.
Tools Needed to Install Fypon Beam Top and End Caps
- Jigsaw with a 45-degree cutting angle and a fine-tooth blade
- Round file
- Small planer
- Caulk gun
- Measuring tape
- Painter’s tape
- Safety glasses
Fypon Beam Top and End Cap Installation Instructions
Step 1: Measure your beam and beam top to the length required; using a square, mark the beam on the sides, bottom and beam top at the desired cut length.
Step 2: Square the beam using small cut blocks of polyurethane or other material along the length of the beam. This will ensure proper alignment of the beam top.
Step 3: Using the jigsaw with fine-tooth blade, cut beam and beam top to marked length (cutting all sides of the beam.) Note: To ensure a straight cut, you can use the square as a guide.
Step 4: Turn beam with open cavity facing upward and place the beam top on the beam to ensure the beam top and beam are at the same length. Note: If any minor trimming is required on either the beam or beam top, this should be done now.
Step 5: After the beam and beam top have been cut, tape in several places along the length of the beam or clamp beam top to the open beam.
Step 6: Place the smooth side of the beam end cap against the end of the beam — determine which portion of the beam end cap façade you want to capture based on your preference.
Step 7: Holding the smooth side of the beam end cap to the cut beam end and beam top, trace the outline of the beam and beam top onto the end cap. Note: Designate the beam end cap as top and bottom with the following marks (B — bottom), (T — top.)
Step 8: Using the jigsaw, cut the beam end cap along the marked line on the smooth side of the beam end cap. Note: Round the edges where marked.
Step 9: After the beam end cap has been cut, move the jigsaw bevel gage to a 45-degree angle. You are going to miter cut the beam end cap with the grain side up (make sure the miter is placed at the correct angle.) Begin cutting by following the grain profile, using the painted edge as your guide.
Step 10: Now, cut the beam top to fit the beam end cap at the same miter angle. Cut at a slight angle to follow the curve of the beam top. Note: Be careful when you reach the edge of the beam top — extra material can be trimmed, as needed.
Step 11: Now, miter the beam to accept the end cap. With the open side facing you, and using the same miter angle as the beam end cap, begin cutting the beam side.
Step 12: Rotate the beam so the open end is sitting flat on a work surface. Start cutting the bottom of the beam at a slight angle until you can get at straight 45-degree angle.
Step 13: Turn the beam with the open side facing away from you, and begin cutting the final side.
Step 14: To clean up corners on the bottom of the beam, change the direction of the miter to the opposite 45-degree angle and begin cutting around the beam bottom. Turn the beam as you go around it.
Step 15: Place the beam top back onto the beam (tape in place) and dry fit the cut beam end cap to the beam.
Step 16: Determine where the beam top and beam must be filed for beam end cap to fit securely. Using a rasp and/or file, shave the interior of the beam miter along the bottom, corners and sides of the beam. Do the same for the beam top.
Step 17: Again, dry fit the beam end cap to the beam and beam top. Determine where you need to sand the beam end cap to achieve a finish fit. Starting with the grain side up, use a rasp and/or file to shave the mitered edges on the beam end cap where necessary.
Again, fit beam end cap to beam and beam top and continue to sand, as needed, for final fit. Note: Once you are satisfied with your final fit, file the edges of the beam end cap to flow seamlessly into the beam and beam top.)
Repeat Steps 5-17 for the other end of the beam.
Step 18: Now, place a thin bead of adhesive, such as PL Premium®, along the edges of the beam and place the beam top on beam. Tape in place.
Step 19: Now, place a thin bead of adhesive, such as PL Premium®, along the mitered edge of the beam end cap and beam, wiping away any squeeze out of the adhesive.
Step 20: Using painter’s tape, tape the beam end cap to the beam to secure the beam end cap until the adhesive dries. Once the adhesive dries (use recommend drying time specified by the adhesive manufacturer), your beam is ready to paint or stain and then install.
For staining tips, reference our “How to Stain Faux Woodgrain Beams and Products Like a Pro” blog post.
Tip: If desired, after the adhesive dries, you can also use a finish nail gun to ensure beam end and top are secured. Use small finishing nails with proper PSI settings based on the nail gun used.
Looking for more ideas on how to enhance the look of your Fypon woodgrain beams? Read our blog post for inspiration on accessories or our blog post “Five Creative Ways to Incorporate Exposed Beams into Interior Designs.”