Jon McFadden
05-29-2005, 08:20 PM
Top Bar
The most important dimension in making top bars using my method is getting the lengths accurate. All cuts are measured from each end of the bar, instead of from a common benchmark.
1. Cut all 1X material identified for top bars using a radial arm saw with an accurately positioned stop at 19”. A chop saw would do as well.
2. Set the rip fence on the table saw to dimension the width of the top bars at 1-1/16”. A band saw could be used for this as well.
The blank is ready for finishing.
3. Using a combination blade, plough a 1/8” kerf the length of the endbar at a depth of 5/16” to 3/8”. This is the groove the foundation will rest in.
4. Set up a dado blade to cut a 3/8” width. Set the depth of cut to 5/16”. Set the fence to make a 15/16” cut from the end to the deepest position. Cut a groove the width of both ends.
5. Reduce the depth of cut to 7/32”. Rotate the endbar to groove both sides on each end.
6. Replace the dado blade with a combination blade. I use a tenoning fixture to make the last cut. This isn’t necessary, but is faster for me. Using the fence set to cut a slice of the end of the endbar 15/16” deep and 5/8” wide. This will leave a tongue 5/8” thick 15/16” long.
Bottom Bar
The material for the bottom bar is the last class of wood. The only thing that this material requires is that it is clear, and I can cut a piece of wood 5/8” X 3/8” X 17-3/4”.
Jon
The most important dimension in making top bars using my method is getting the lengths accurate. All cuts are measured from each end of the bar, instead of from a common benchmark.
1. Cut all 1X material identified for top bars using a radial arm saw with an accurately positioned stop at 19”. A chop saw would do as well.
2. Set the rip fence on the table saw to dimension the width of the top bars at 1-1/16”. A band saw could be used for this as well.
The blank is ready for finishing.
3. Using a combination blade, plough a 1/8” kerf the length of the endbar at a depth of 5/16” to 3/8”. This is the groove the foundation will rest in.
4. Set up a dado blade to cut a 3/8” width. Set the depth of cut to 5/16”. Set the fence to make a 15/16” cut from the end to the deepest position. Cut a groove the width of both ends.
5. Reduce the depth of cut to 7/32”. Rotate the endbar to groove both sides on each end.
6. Replace the dado blade with a combination blade. I use a tenoning fixture to make the last cut. This isn’t necessary, but is faster for me. Using the fence set to cut a slice of the end of the endbar 15/16” deep and 5/8” wide. This will leave a tongue 5/8” thick 15/16” long.
Bottom Bar
The material for the bottom bar is the last class of wood. The only thing that this material requires is that it is clear, and I can cut a piece of wood 5/8” X 3/8” X 17-3/4”.
Jon