I need to cut a tenon on the hexagonal base a fairly large turned newel. I need to end up with a 1/2″ shoulder on 5 of the eight sides and a 2″ shoulder on the opposite side. That side is where it will attache to the stair stringer and joist below. I was planning to make a jig to let my router cut out the waste, but since I always get great ideas here, I thought I’d run it past the crowd. It’s fairly big (~6″ dia) and fairly heavy (30 lbs +/-), so manuvering it around on a stationary tool doesn’t sound practical. Any ideas?
PS attached drawing might make this more clear
Replies
Use hand saws. Cut the shoulders with a cross-cut tenon saw and begin the rips with a rip-filed tenon saw and finish with a panel saw unless you have a really deep cutting tenon saw (didn't see the depth dimension on the drawing).
Deep tenons have been cut with panel saws for a long time. Tis how I was taught.
Take care, Mike
I notch a lot of newels. I use a circular saw and set the depth. Make a series of kerfs close together, about 1/8", down the length of the tenon. This will result in a bunch of thin, crosscut leaves that will break off easily. Clean up the surface with a paring chisel and/or block plane. You would have to set the depth at 1/2" for three of the facets and whatever it is for the deep notch. Take the time to make plenty of closely spaced kerfs.
You may want to cut the visible shoulder cuts with a hand saw, for a cleaner cut. If you start your kerfs from the far end and work up to the shoulder, you won't be riding on the rough kerf cuts. Same way on the face, turn the post away from you as you progress from facet to facet. The only trick is keeping the saw flat on the surface to maintain consistent depth of cut.
Beat it to fit / Paint it to match
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