How TimberVolt® Power Posts Are Made
How Are TimberVolt® Power Posts Made?
TimberVolt® power posts are patented, pre-wired timber posts that carry concealed electrical wiring straight through the center of solid timber (U.S. Patent No. 10,053,861). Part of the TimberVolt® power system, each post is core-bored, hand-fitted, and shop-tested to bring hidden outlets, switches, USB and TV ports, and lighting or fan controls to a pergola, pavilion, or outdoor space — with no exposed conduit or surface wiring.
So how do you run power through solid wood? It takes more than a long drill bit. It takes proprietary tooling, trained timberwrights, and real respect for the grain — here is exactly how every post is made. When a project needs engineering proof, Western Timber Frame supplies permit-ready structural drawings and arranges an engineer’s stamp where the jurisdiction requires one.
Built and Inspected in Our Own Shop
Every Power Post is made in-house at our Utah shop — not sourced or assembled from outside parts. Even though the work stays in Utah, Western Timber Frame publishes one price nationwide, in state and out.
The wiring channel is bored end to end through solid Douglas Fir, Coast Redwood, or Cedar.
Each post is checked by hand before it ships, so the concealed power arrives ready to install.
Why We Built TimberVolt®
Outdoor power has traditionally meant exposed conduit, extension cords, or wiring added after construction. We believed there had to be a better way. TimberVolt® was developed to integrate electrical power directly into heavy timber — so outdoor structures could stay clean, beautiful, and ready for modern living.
How a TimberVolt Post Is Made, Step by Step
What looks simple from the outside is a careful sequence of joinery, boring, and electrical work — every step done in our Payson, Utah shop before a post ever ships.
Cut to Length & Dovetail Joinery
Each post starts with precision sizing and our patented Dovetail Difference® joinery — for structural strength and a clean architectural finish.
Box Cavities Cut for Switches & Outlets
Using a chain mortiser, our timberwrights hand-cut recessed cavities for switches and outlets, working around knots, curves, and grain. Each box takes 7–45 minutes, depending on the wood.
Boring the Power Core
A proprietary air-assisted horizontal boring system cores the post in 20–100+ controlled passes to stay centered and avoid blowouts. An 8-foot post takes about 90 minutes — add roughly 15 minutes per extra foot.
Electrical Boxes & Protective Steel Sleeve
Recessed thermoplastic boxes — UL-listed and fire-rated — are secured in place, and a protective steel sleeve is inserted through the core so lags and screws can’t puncture the wiring during installation.
Wiring, Switches, USB & Weather Covers
Every model is fitted with outdoor-rated, UL-listed wiring, then outlets, USB and TV ports, switches, and fan or light controls — finished with weatherproof Hubbell® (or equivalent) covers.
Testing & Final Finishing
Every post is electrically tested, then stained and finished — ready to install and power up the moment it’s set in place.
The TimberVolt® Models
Choose the level of power that fits your space — from a single switch to a fully loaded post with outlets, USB, and a TV port. Every model is pre-wired and shop-tested before it ships.
Firefly™
Simple, functional power
- Drilled for 1 light switch
- 1 recessed outlet box with cover
- Metal pipe cover on top for protection
Phoenix™
Light + outlet combo
- Drilled for 1 light switch and 1 outlet
- 2 recessed boxes with covers
- Metal pipe cover for clean top access
Dragon™
Pre-wired, plug-in-ready
- GFCI outlet and light switch pre-installed
- Bottom male plug, top female plug
- Weather covers and boxes included
Inferno™
Fully loaded power post
- Dual outlets, USB, GFCI, and TV port
- Fan switch and light switch
- Protective steel sleeve and weather covers
Drill For Power™
Ready for your electrician
- Post precision-bored and prepped
- Run your own wiring configuration
- The flexible, build-your-own option
See every model and custom wiring option on the TimberVolt® power system page
Who Is TimberVolt® For?
Concealed outdoor power fits anywhere people gather outside — from a backyard patio to a public park.
Why It Matters
Built Strong
Most TimberVolt® posts are crafted with the Dovetail Difference® — our signature interlocking joint that locks timbers together without relying on metal fasteners, for lasting strength and a clean finish. (Some custom Drill For Power setups may vary.)
Built Safe
Every post includes UL-listed wiring, GFCI outlets, USB ports, and weather-resistant covers — so your power stays protected in any weather.
Built Clean
All wiring runs inside the timber. No visible conduit, no trenching — just clean lines and a flawless finish.
Built Ready
Most TimberVolt posts arrive pre-wired and plug-in ready — simply connect and enjoy. Prefer to run your own configuration? Choose Drill For Power.
“Every timber has its own grain, character, and challenges. Precision comes from understanding the material—not fighting it.”
— Hyrum Thompson, Founder & Inventor, Western Timber Frame
What Is Inside a TimberVolt® Power Post?
From the outside, a TimberVolt® Power Post looks like a solid, handcrafted timber column. Inside, it holds a carefully planned pathway for electrical wiring, protective components, and weather-resistant power connections.
The exploded diagram shows how these components work together. A precision-bored channel carries the wiring through the solid timber, while an internal protective steel sleeve helps protect it from compression and movement. Recessed electrical boxes, code-appropriate wiring, and weather-resistant covers integrate convenient power into the post — with no exposed conduit running across the finished structure.
Concealed by Design
Creating a clean pathway through a solid heavy-timber post takes far more than drilling a single hole. The channel must stay properly aligned through the timber while preserving the post’s structural form, exterior craftsmanship, and finished appearance.
Western Timber Frame developed a specialized, multi-pass boring process to create this internal pathway with precision. Once the channel is complete, the steel protective sleeve, wiring pathway, electrical boxes, outlets, and covers are prepared as an integrated system.
The result is power that feels like part of the structure rather than an addition to it. Lighting, fans, televisions, charging devices, speakers, and other outdoor amenities can be planned without loose extension cords or distracting surface-mounted conduit.
Every TimberVolt® Power Post begins as solid timber — Douglas Fir, Coast Redwood, or Cedar. It is precision bored from end to end, carefully mortised where electrical devices are required, fitted with a protective steel sleeve, then inspected before finishing. The result is concealed power that preserves the beauty and structural integrity of the timber.
How Every TimberVolt® Power Post Is Made
Every TimberVolt® post is built by hand by Western Timber Frame’s timberwrights — craftspeople trained in traditional timber joinery. Power runs through a 1.25-inch channel bored down the center of the post, with the outlet, switch, and light boxes mortised into the timber at the heights you’ll actually use them. The wiring is run to National Electrical Code (NEC) standards, fully concealed inside the timber.
Drilling that channel is the clever part. The bit is eight feet long, so each post is drilled from both ends — which is how power can run up a post as tall as sixteen feet. Timber is never perfectly straight, so as the bit travels it wants to follow the grain and drift. Each mortised box becomes a place to stop, re-center the bit, and start clean again. Without those boxes, a long post can take several attempts — and several ruined timbers — before the channel runs true. With them, it’s a reliable, repeatable process that keeps the hole dead-center instead of drifting out the side. Even so, timber is a natural material — knots and grain mean not every post makes the cut, and the ones that don’t run true are set aside.
The channel is small relative to the timber, so it doesn’t take the strength out of the post — the post is still the post. What you’re left with is a clean timber with no visible wiring, no surface conduit, and no clutter — concealed outdoor power, simply there when you need it.
TimberVolt® in Real Spaces
From lamp posts and string lights to outlets and outdoor TVs, here is concealed in-post power at work in real Western Timber Frame projects.
Ready to add hidden power to your space? Explore the TimberVolt® power system
Ready to Power Your Outdoor Space?
Bring clean, concealed power to your pergola, pavilion, or gazebo with patented TimberVolt® in-post wiring. Tell us about your project and our team will help you choose the right model and layout.
TimberVolt® Power Post FAQs
What are TimberVolt® power posts?
TimberVolt® power posts are patented, pre-wired timber posts that carry concealed electrical wiring through the center of solid timber (U.S. Patent No. 10,053,861). They bring outlets, USB and TV ports, lighting, and fan controls to a pergola or pavilion with no exposed conduit. See the full system ›
How is the wiring hidden inside a timber post?
The wiring is hidden because each post is core-bored down the center with a proprietary air-assisted boring system. A protective steel sleeve is inserted through that channel to protect the wires, and recessed boxes house the outlets and switches — so nothing is visible on the surface.
Are TimberVolt posts safe?
Yes. TimberVolt posts are built using UL-listed electrical components — including UL-listed wiring, GFCI-capable outlets, and rated boxes — along with weather-resistant covers and a protective internal steel sleeve that shields the wiring. Final electrical connections should be completed by a qualified electrician in accordance with local electrical codes.
What does “UL-listed” mean?
UL-listed means a component has been independently tested by Underwriters Laboratories (UL) and meets recognized safety standards for its intended use. Western Timber Frame builds TimberVolt posts using UL-listed electrical components — so the posts carry UL-listed parts, rather than being certified as a whole assembly.
What size timber post is needed for in-post power?
In-post power is built into posts that are 6×6 or larger, which leaves enough solid timber around the bored channel for strength. Posts can be powered up to roughly 16 feet in length.
Does drilling for wiring weaken the timber?
No. The channel is bored only through posts that are 6×6 or larger, so plenty of solid timber remains around it and the post keeps carrying the structure exactly as engineered. The wiring pathway is planned within those structural limits — it runs through the middle of the timber rather than taking away from its job.
What can a TimberVolt post power?
A TimberVolt post can power standard outlets, GFCI outlets, USB charging, an outdoor TV, string lights and post lamps, and fan or light switches — depending on the model you choose.
Can a TimberVolt post power a ceiling fan?
A ceiling fan mounts overhead rather than on a post, so the fan itself is fed by our Drill For Power option, which routes concealed power up through the structure’s timbers to the fan location. The post can still carry the fan’s switch or control, along with outlets and lighting.
Do TimberVolt posts come pre-wired?
Yes. Most TimberVolt models arrive pre-wired and shop-tested, ready to power up on install. If you prefer to run your own configuration, the Drill For Power option ships the post precision-bored and prepped for your electrician.
Can the wiring be replaced later?
The wiring runs through a planned internal channel and a protective steel sleeve, so it can be accessed if it ever needs updating. In practice, we have not had to replace it.
Are TimberVolt posts weather-resistant?
Yes. TimberVolt posts are built for the outdoors — outdoor-rated wiring with high-performance jackets, weather-resistant seals, and weatherproof-rated covers (Hubbell® or equivalent) — so they hold up to real-world outdoor conditions.
Can a TimberVolt post be used indoors?
Yes. TimberVolt is designed for outdoor living structures, but the same concealed-power posts work just as well in indoor timber structures.
Which TimberVolt model should I choose?
It depends on how much power you want. Firefly covers a single switch, while the Inferno is fully loaded with dual outlets, USB, GFCI, and a TV port. Compare every model on the TimberVolt® power system page.
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