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The money-smart (and attractive) way to build thick legs

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Build a sled for accuracy

Build a sled for accuracy

The sled shown right carries the leg stock through the tablesaw blade safely while ripping each piece to identical width. Build it from dead-flat plywood or MDF. Bevel-rip the base, and then attach the fence 1 1/2" from the beveled edge. Use a leg piece to help position the cleats at each end.

Position the toggle clamp so it applies pressure 3/4" from the edge of the fence. This prevents the leg face from tipping when beveling the second edge.

Next, test (and tweak) the tilt
Before cutting into your good stock, adjust your tablesaw bevel angle to exactly 45° by making bevel-rips in four identical-width pieces. Assemble the test pieces, and, if all four corners close tightly, you're ready to begin. Lock the blade-tilt mechanism on your saw to prevent the blade from shifting.

Continued on page 3:  Set up the sled; then rip


Comments (3)
genesent4u wrote:

Great tip. It should help me solve a problem I am working on. Have you thought that this may be a good way to dress up the legs and borders on whatever your building? Cut the 1/4" deep kerf a bit wider and on all four side of the legs and edges of the top from a different type of wood for accent strips? I think I will give it a try on a project I am planning. Thanks again for a great tutorial.

1/9/2016 06:02:43 PM Report Abuse
JimTheSoundman wrote:

Rjoy, I think they were saying that although there the piece of wood you are cutting will be the correct length, you should make the sled a bit shorter so it doesn't touch or interfere with the blade, as that might throw off the actual work cut. At least that was my take on it.

8/6/2015 05:47:48 PM Report Abuse

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