Hi, I am building an Arts & Crafts Table Lamp out of oak; the plans came from another woodworking magazine. The shade is mica and has (16) pieces of oak, 1/4″T x 1/2″W and 4″ to 17″ long. They require a 24-degree bevel and a 39-degree half lap on the ends. It is a lot of work to make pieces this size, before you even start putting the bevels and laps on them, there is a lot of getting close to blades. A lot of push sticks and such.
I am getting tear out on the ends even using a guard block to firmly cover and hold the piece down. I am using a table saw and Incra jig to cut the 39-degree angle. I am having to re-work 3 peices due to tear-out now and I am wondering if a table saw is the wrong tool, I also dislike making small wood cuts on a 12″ miter saw. A handsaw would not be accurate enough and can’t make the half laps, I figured that would be a dado blade.
Are small pieces of wood just difficult to work with any tool? I am using good 60T crosscut blade and wood push blocks to hold pieces down. (hoping to reduce tear out) Tear out has ruined a couple of pieces, another jumped on me and a big chunk came off, scary. I don’t want to repeat this process. I have to make most things a few times to get them right, these seem extra complicated and challenging.
Any insight would be welcome. Thanks
Kurt
Replies
Stop! Cut enough pieces like this, you'll hurt yourself. Badly.
Cut pieces slightly oversize by hand. Use a shooting plane to get a perfect final fit. Or make a block with the right angle and use a paring chisel.
Take a look at how the kumiko people Cut tiny parts to the perfect size.
Keep all your fingers attached.
Small parts can be done at the tablesaw without tearout if you build dedicated zero-clearance sleds for each operation.. in this case lefts and rights for the bevels & laps. A digital angle gauge like Wixey makes will help a ton if it's in the budget.
The thin stock should be ripped off a wider board so the user piece falls away as the cutoff. Make extra; you'll miss on some joints and be glad to have it waiting.
If you are uncomfortable doing something with dangerous equipment, you shouldn't do it. It may be fine for others, but being nervous about it might make it more likely for you to have an accident. There are always other ways to do something, especially as a hobbyist since you aren't needing to do it quickly. Working small pieces with power tools is never a good idea. If you must, try to work a long board, with the last operation being to cut off the small piece. I would also highly recommend using hand tools for small pieces.
Thanks all, careful, careful, careful!
Using tape on the area you are going to cut will reduce tear out meaning you cut through tape and the tape holds the wood down on the ends