I’m a rookie building 9 sets of simple 6″ 8′ long box columns for an outdoor project — using hand held power tools. Design is simple glued butt joints. I won’t bore you with the milling challenges (used the cutting board in recent FWW with success) but I have successfully glued up the two narrower boards to one wide board to form 9 sets of U’s.
Problem is: my glue up jig (and technique) was less than perfect — and while the joints are nice and tight (externally), many of the sides are set at a slightly greater than 90 degree angle. Result is (1) remaining side needs to be approx 3/16″ wider to cover gap and (2) the edges are not parallel to the wider boards.
Note: I am one avoiding potential solution — drawing the sides together with pressure — and affixing the remaining side to hold everything together. Reason: I don’t trust the glue and joints in this exterior situation.
Questions:
(1) What is the best technique to bring the narrow edges parallel to the wide boards to allow for tight joints (remembering no stationary power tools)? I can’t imagine doing this successfully without some sort of reference or jig.
(2) Am a missing a better approach?
Thanks in advance for any help. (And I’ve already learned many hard lessons on getting it right up to this point).
Ken
Replies
Ken,
As you probably suspect, there is no easy fix at this point. Why didn't you glue up all 4 sides at the same go? Be that as it may...
Put them in a pickup, and take 'em to a shop that can run them through the machines for you. You can square the sides on a jointer first, then take a pass on the planer to fix the exposed edges for gluing. All in all it's only a half-hour's work.
I know you said no stationary tools, but you don't have many alternatives, aside from scrapping them and starting over.
Sorry to be so pessimistic, but it's best to cut your losses and move on.
DR
Thanks for your response. I appreciate the candor.A couple of clarifications: 1. I am only seeking to make the narrow board edges parallel to the wide boards. I am not trying to recreate a perfect box column by planing the sides of the narrow boards. I can live with the columns being out of square by the 3/16" since I don't think anyone will notice after sanding the edges of the final wide board to the same plane as the narrow boards (if this is even necessary).I was thinking about about how to jig (rig) up a belt sander to (un) true up the narrow edges.2. Why not do all four sides at once? These are structural post wraps, and conventional wisdom is that its best to complete three sides first (correctly, of course), attach the U-shaped wrap to the post (with all the right ventilation, etc.) and then attach the final board.Hope this helps inspire another thought.Thanks.
Ken,
I don't think the belt sander will do anything more than create new problems. If you have a router table, set a straight bit in the router and run the columns past it, with the fence set to just a bit less than the current width of the column. Just enough to touch lightly on every spot of the edges. If the columns are bowed, use a short piece of fence so you're not fighting the bow while doing this. Fixing it with the circular saw is a last option, and isn't even worth trying if the saw is not perfectly tuned and sharp.
DR
Clamp a straightedge on the narrow board, then use either a handheld circular saw or a router with a straight bit.Put a rip blade in the circular saw, or a combination blade if you don't have a rip blade.This will square up the narrow boards and make them paralell in the same cut.Your saw base was probably out of square to the blade the first attempt. Make sure you square up the base first.
The router will be the easiest for you, if you have one already.
mike
Personally, I'd trust the glue joints in bringing the edges together 3/16"- But if you're going to paint this anyway (?), you can set some finish nails, use wood dough, sand, primer & paint- No?
I'm old and got really lost on the post.. Not really sure what you did OR are doing..
If a problem I'd just rip down the length to cut it apart.. I assume a good saw guide... Fix what is broken and re-glue!
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