I am about to make my porch balusters.
Attached is a simple example of my design.
I’ll be using 1x stock.
Based on my availability of tools, I propose to use my router to make the “cuts”
I need to make some sort of template.
I was wondering if you’all could offer up some tips.
1) whats a decent cutting bit
2) what are some approaches to making a template
3) other
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Many of you (as well as the Forum in general) have offered me loads of tips and assistance on “My Summer Project”, I promise I will have some pictures very very soon.
I wanted the outside to look half way decent. I’ts been quite a ride the last 19 months
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WWPD
Replies
Going for the rustic or kindergarden look, Got it. Use a skill saw and be sure to wabble the saw as you go.
Just kinding. Your drawing is a bit rough. LOL.
But really, a skill saw might not be such a bad idea. Some 30 years ago I built a deck and balcony with very , very, similar slates. Kind of a Swiss Challea (spelling?) look with nothing but skillsaw, handsaw to finish the cut, and a rasp for clean up.
A router would make for very clean cuts, but a lot of work.
Try one board and see how it goes.
Here's how I'd do it:
1. With a bandsaw or jigsaw make a template from some stable, dense material. I like to use 1/2-inch baltic birch plywood, but a piece of 3/4-inch hardwood would work.
2. Using the template and a pencil, trace the pattern onto the baluster material.
3. With a bandsaw or jigsaw, cut close to the pencil line, leaving about 1/16 to 1/8 inch of waste.
4. Attach the template to the baluster over the traced pattern with double-sided carpet tape.
5. Using a "pattern" or "template" router bit (one with a bearing on the shank above the cutter), cut to the pencil line. The bearing on the bit should ride on the template, while the cutter should trim the small amount of waste material remaining on the baluster. A simple router table, like a piece of MDF laid across two sawhorses, would really facilitate this step.
That sounds promising.
I am poor at using drawings.
The lines are not all straight, there will be curves. However with the jig/band saw I should still be able to get tight to the lines, before the router does it's thing.-----------------------------------------------------------------------------
WWPD
SLOapo gives good advice. I might change one thing. If I had a bunch to do I'd probably rig a clamp system on my template so I didn't need to mess with the tape each time. Maybe run long and cut to length after routing to avoid router interference at ends. Design would dictate method, me thinks.
Google DeStaCo for some clamp possibilities.
If they're getting painted, I would look at running a couple of screws through jig into stile and fill them when painting.PJ
Everything will be okay in the end. If it's not okay, it's not the end.
I third SLOSapa and second PeterJ. But instead of using clamps, just run the piece long and affix the template to the original with two screws, one on top and one on bottom. This way the clamps won't get in the way on the router table.
Heck, if you're going to paint these, you don't even need to make them long. Just put the screws through the template into the piece and fill the holes later. It's a trade off between filling holes or cutting the top and bottom off of each piece. “The richest genius, like the most fertile soil, when uncultivated, shoots up into the rankest weeds..” – Hume