Now that all of the pieces were cut to final dimensions it was time to get cracking on the joinery. I laid out the positioning points for the halved joints on one of the longer base pieces with the intent to set up stop blocks on the cross-cut sled.
With the first stop block in place, I used one of the shorter base pieces to set the width that will be created by the second stop block. From the title of this post, you’re anticipating something going wrong…and some of you wiser folks might even see it already!
Here’s the sad part…not only am I going to miscalculate this cut, but I think I’ll stop and take a picture of it. J
In a fevered moment of personal triumph I grabbed one of the smaller base pieces to test what is sure to be a nice, snug, precise fit…
As soon as I saw that extra little gap, around…oh let’s say…1/8 of an inch…the exact width of the table saw blade…the palm of the hand meets the forehead! At this point I’m really sorry that I didn’t cut an extra 10 inch piece to use for set-up…now my forehead is really getting sore!
Let’s just call this a teachable moment and move along, eh? You can see here that when I place the shorter base piece along the far edge of the joint, the blade fits right into the remaining gap.
With a cold compress on my forehead and the stop blocks set correctly, the next cut produced exactly what I was looking for…a clean looking joint with a snug fit.
I went ahead and cut the joints on the replacement piece and then used the good cut on the test piece to fine tune the fit. I did need to raise the blade just a hair more, but I’ve now got the sled dialed in to produce some really nice halved joints.
And with that, rather than flirt with disaster, I went to bed. I’ll finish cutting these joints on Sunday!
Rock on fellow Eagles fans!Pete