I'm almost ready to insulate the (now) vaulted ceiling in my garage project (ref. https://www.garagejournal.com/forum/threads/raising-garage-ceiling-questions.500414/). The existing rafters are only 2 x 6 and while they do the job, I want to add more than R19 insulation without spending the $$$ on foam. I also plan to install a ridge vent and eave vents, so must account 1.5 - 2" for that. I'm looking for options to extend the rafter depth to allow more insulation. Rafter are ~13' long and I considered adding a 2 x 4 edge-wise to the existing 2 x 6. I did a test fit up and am not sure this is the way to go. It will be very difficult to get the fit close enough to make a good glue joint along the length, so I don't think I'll get much out of it structurally speaking. I can use Timberlok 6" screws to hold them in place, but would rather do something that would be easier to install and if not stiffening the rafter, at least not adding much dead weight to them. I plan to use metal sheet to cover insulation to minimize extra mass. One approach that I read about suggested using plywood or OSB gussets to attach 2 x 2 at whatever extension I choose. Gussets would certainly be easier to attach to existing rafters and might even add a little stiffness. Anyone have experience doing this?

