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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 (1)
rjoy205 wrote:

The only thing about this technique that I do not understand is that in the 3rd step (i.e., Set up the sled; then rip), the first bevel cut is done with the sled positioned 1/16" away from the blade. Wouldn't this result in the finished / final product being 1/16" wider than it's supposed to be? Why aren't both cuts made with the sled against the blade?

1/4/2014 04:56:59 PM Report Abuse

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