This tutorial was created by Matt from Next Level Carpentry. It walks through the process of laying out and cutting beautiful elliptical shapes on pergola joists, using simple tools and smart techniques to achieve professional-quality results.
Decorative ends can turn a plain pergola into a standout feature. With careful layout and basic woodworking skills, Matt shows how to create clean, consistent curves that add lasting style to outdoor structures.
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Why Add Decorative Ends to Pergola Joists?
Adding a decorative cut to the ends of pergola joists gives the structure a finished, elegant look. Even a small detail like an elliptical curve can change the whole visual impact of a pergola.
While freehand methods might work for one-off projects, Matt’s approach focuses on repeatable accuracy. By creating a pattern and using a router, the end results are cleaner, more consistent, and faster to replicate.
Laying Out the Elliptical Pattern
The first step to getting a perfect cut is understanding the layout of an ellipse. Every ellipse is based on two measurements: the major axis (long side) and the minor axis (short side).
Matt explains how to determine these dimensions based on the size of the pergola joists. Once these two key measurements are set, the rest of the process falls into place much more easily.
Making a Guide Stick
To draw the elliptical curve accurately, Matt builds a guide stick. This simple tool is made from a straight piece of scrap wood that’s longer than the combined major and minor axes.
Small holes are drilled into the guide stick at the correct points for the major and minor axes. A mechanical pencil fits into a center hole, and guide nails at the endpoints keep the stick aligned during drawing.
This setup allows the pencil to trace a quarter ellipse with smooth, even curves—far easier than trying to freehand the shape.
Tracing and Shaping the Template
With the guide stick ready, it’s time to trace the elliptical pattern onto a flat, manageable material like melamine MDF. This material holds a pencil line clearly and cuts cleanly with saws.
After tracing, the rough cut is made using a bandsaw, jigsaw, or scroll saw. Matt leaves a small margin outside the pencil line during cutting, giving room for refining the curve accurately afterward.
Sanding smooths the cut edge into a fair, consistent curve. Clamping the template into a vise makes it easier to work carefully, starting with coarse sandpaper and finishing with finer grits for a polished edge.
Cutting and Refining the Template
A smooth, even curve is essential for routing, so Matt spends extra time ensuring the template is as close to perfect as possible. Any bumps or flat spots will transfer directly to the pergola joists during routing.
He also adds a slight angled cut at the end of the ellipse for a more dynamic look. This small detail gives the pergola joists an even more custom, high-end appearance.
Once satisfied with the template, it becomes the master pattern for all the joist ends.
Transferring the Template to Joists
To mark the pergola joists, the finished template is positioned at the end of each board. A pencil is used to trace the shape directly onto the joist.
Matt cuts close to the line using a jigsaw, staying just shy of the final shape to avoid mistakes. This rough cut sets up the joist for a cleaner finish pass with the router.
Using a Router for the Final Cut
With the rough cut complete, a flush trim router bit is used to clean up the shape. The bearing on the router bit follows the edge of the template, ensuring that each joist matches the pattern exactly.
Proper setup of the router bit is crucial—Matt makes sure the cutting edge is aligned perfectly with the pattern to avoid any steps or uneven surfaces. With a steady hand and a sharp bit, the router delivers a crisp, clean final shape.
Creating a System for Production
By following this method, the process becomes highly repeatable. Trace, rough cut, and route—those three steps turn each joist into an exact match of the original design.
This is especially helpful for larger pergola builds where multiple joists need identical decorative ends. By turning the method into a system, Matt saves time and ensures professional-quality results across the project.
A Small Detail That Makes a Big Difference
Decorative ends may seem like a small addition, but they make a big visual impact. Clean, elliptical curves elevate the entire structure and demonstrate the kind of attention to detail that sets a woodworker’s projects apart.
Using this method, even beginner or intermediate carpenters can achieve consistent, beautiful results without the need for specialized equipment.
Conclusion
Cutting decorative ends on pergola joists doesn’t have to be complicated. With a simple guide stick, a well-shaped template, and careful use of a router, anyone can add this elegant detail to their outdoor projects.
Matt’s method provides an easy-to-follow approach that emphasizes precision and repeatability. It’s a great technique to add to your woodworking toolbox, especially for anyone who enjoys building pergolas, decks, or other outdoor structures.
Watch the full video and subscribe to Matt’s channel: