Thanks
Bret, you always offer good advice and encouragement. Funny you mention the sugar trick, I had seen Paoson woodworking on YouTube often uses salt, and was going to try that but forgot! I do have a table saw jointing jig, but I made it in a pinch last year and the clamping mechanism is not good, especially for pieces this tall.
I ended up using the router and flush trim bit to get one side reasonably close:
Then stacked them together and did some brief sanding:
At that point each leg had one side that was looking pretty decent, definitely good enough to run through the table saw, so I just ripped the other side straight, in two passes, flipping it over. The height of these edges were 2 1/4" so that's a tall order for my job site saw when it's maple.
From the flip-over and essentially resawing on the table saw, there was still a slight lip so I then ran
that side through the router table.
Then I could sand each piece individually. A few notes on the Festool sander, my first time using it outside of a quick test...
- it's hefty, and not quite as ergonomic as I'd hoped (might be personal preference)
- it jumps around the workpiece a bit, skittish, not that steady. Could be my technique. I tried various speeds and none were quite as smooth as my DeWalt. I wondered if it was the orbit pattern or their special sandpaper. Only 1 sheet came with the sander, 120 grit. If anyone has this model and has advice I'm all ears, essentially what I mean is it feels hard to control.
- the finish it leaves is very good
- takes a while to remove material... almost feels under powered
- dust collection is truly excellent. Better than the DeWalt. I didn't really notice any dust at all. And after 30min of sanding the sandpaper still looks brand new.
Finally I cut all the legs to length. To do this I clamped a 48" length of Incra TT+ and stop to my little crosscut sled. I bought it for the fence for this tracksaw station, and it's been sitting around since the beginning of the summer. I can't believe I've never thought to use it on the sled before. Helped keep the leg heights extremely accurate and consistent.
And allows for plenty of length of repeatability!
Overall pic of the shop for fun, it was about 30 F out there this morning!
In the end I ended up with 5, relatively square legs. Measuring 1 7/8" x 2" instead of 2" x 2" like originally planned, but not a big deal.
So far this project seems to be moving along, hopefully I can keep the momentum going!