Replies

1. 
   eddiefromAustralia | Mar 14, 2006 09:04pm | #1

   Guppy,

   Handsaw??

   Cheers,

   eddie

2. 
   douglas2cats | Mar 15, 2006 03:10am | #2

   Is the notch actually 4" deep? Or are you making something like a half-lap joint to mate two 4" thick pieces? If it's the latter, I think I'd try a straight edge guided circular saw making multiple passes then chisel out the waste. Or maybe even a router and jig.

   If you build it he will come.

1. 
   Guppy | Mar 15, 2006 04:22pm | #3

   Thanks for the responses.  I am making two 2" cuts so that the stock will fit together like an "x".  (This project is not mine-I am only following directions.)  This will be incorporated into a dining room table design which has a glass top, so the cuts need to be fairly well finished.

   Elliott

1. 
   douglas2cats | Mar 15, 2006 08:04pm | #4

   I kind of figured that's what you were doing. I think I'd go with making a one-time router jig to attach to the boards to plow out the space for the other board (with multiple passes maybe 1/4 deeper each time). You might have to search around a bit to find a router bit long enough, but I think you'd get a flatter/smoother bottom than some of your other alternatives.If you build it he will come.

1. 
   SteveSchoene | Mar 15, 2006 11:50pm | #5

   In my opinion, by the time the router jig is made, the notches could be cut with a hand saw, (or on the band saw) and the waste chiseled out. 

3. 
   TomHigby | Mar 16, 2006 05:11am | #6

   This sounds llike the place for a radial arm saw, making repeated cuts and clearing out with chisel.

   Tom

1. 
   user-120110 | Mar 18, 2006 05:00pm | #7

   try the good old skill saw with a new blade installed ,then a little hand work and your done. KIS(keep it simple)I have made many laps this way,good tight laps, over 35yrs as a carpenter,cabinet and furnitur maker.Cut the left and right sides then hog out in between(kerf), knock out the waste with a chisel,prybar or straight clawed framing hammer, pare the shoulders and bottoms flat. there you go!!

4. 
   BigK | Mar 19, 2006 02:13pm | #8

   Try hogging out most of the cut with a skilsaw and new blade, then finish it/clean it up using a router and a top bearing bit. The router only has to cut the bottom 1/16" or so to get a perfect finish and a beautiful joint. I would recomend that you avoid the recip saw as their blades tend to wander. Don't think that the jigsaw will have the capacity or the umph for such a cut. With the router you may want to make a different base that would span the rabbet cut to better support the motor. But that should only take a couple of minutes, so no big deal.

   
   

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   Edited 3/19/2006 7:25 am ET by BigK

5. 
   h12721 | Mar 22, 2006 02:54am | #9

   Guppy

   By time you wrote this and read all the post you would be finish with a handsaw and chisel'

   Hilmar 

6. 
   PeteBradley | Mar 22, 2006 03:28am | #10

   That is a huge piece of stock for a table! I'm assuming that telephone poles will be used for the legs?

   The circular saw method of carving out square notches is brainless, effective, and fun, and everyone should have it in their bag of tricks. However, at 5" deep in 4" stock I don't think it's a great approach. I think the hand saw Neanderthals win. :-)

   Pete