I am attempting to replicate this flat detail that connects a round leg to a rail.
How would you go about making it?
Here is what I’m thinking:
1 Create a round leg on the lathe
2 Build jig to firmly hold the rounded leg (perhaps a V shaped clamp. shown in cross section below). The jig would have a flat face on the bottom, 90 degrees to the face that needs to be cut.
3 Cut on the bandsaw with the jig. The flat base of the jig would keep the round leg from spinning on the bandsaw.
4 Sand on the spindle sander to refine the shape
Do you see any problems with this plan? My concern is that the plan seems complicated, so you all might know an easier way.
Here it the full bed if you want to see the cut in more context.
Thanks!
Lathe part is fine. I would then clamp the leg to a small sled / jig, and use the router table. Then use a straight router bit (I prefer radial bits). If you can, fit stop blocks to control the length of cut.
I’m coming at this from a simple hand tool perspective:
As far holding a round legs, dowel or similar piece, I’d take a scrap of 2x4 (the length will be determined by the length of the leg in your case) that’s just long enough to provide good stability. I’d cut two opposing 45 degree cuts maybe 3/4 inch deep so you end up with a “V” shape grove along the length. The leg will lay in that grove.
Regarding the flat, first you’ll need to mark the lay out of the length of the flat, and the depth which is very easy. Then I’d simply use a cross cut saw to make stop cuts to at both ends and every inch or so in between stopping shy of the layout line. How close to the depth line depends on your confidence—I’d aim for 1/16 inch shy.
Once you have your stop cuts done, gently chisel out the waste with a sharp chisel. The upper sections will break out quite easily, but you’ll want to be sensitive to the grain and which way it’s running so you don’t split off a piece below the layout line. As you approach the depth layout line, take your time and pare the wood down to the layout line.
It may sound complicated, but it’s actually quite easy and fun. As goes very quickly. That’s the hand tool method in a nut shell.
I’m certain the the experienced CNC folks will be able to design it with software and let the machines go to town. Absolutely nothing wrong going that route as you’ll get amazing results. I’m just not the maker who has that skill set, as love using my hands tools to create.
Good luck! I cannot wait to read further responses and most of all, see your finished bed.
While you still have a perfect square, cut the flat sides using the tapered angle jig (is on the shelf) on the table saw (proably tilting the blade to 45°) then turn on the lathe. It will require a perfect square stock and a very good center when installing on lathe.
