How would you make this leg?

[zeykr]

7844

Have an opportunity to quote this leg. 350 piece initial order and possibility of many more the same and similar.

The customer will do the turning and supply the material, I just need to taper the leg for them to turn. The taper starts below the turning (i.e. 16 3/4" from the bottom). The second small taper will be fitted with a metal cap so it needs a sharp shoulder.

How would you make it?

I though of a) cutting it on the Bot, b) cutting template on bot and routing on router table, or c) what I'm leaning toward is making a couple table saw jigs - one to cut the main taper with the leg lying horizontal on a sled, then a second to cut the small taper with the leg upright on a sled.

What method would you suggest?

Has anyone made jigs or have a design for a jig similar to what would be needed?

[cnc_works]

Looks to me like a job for a simple taper jig.

Unless you have a 12" table saw, you couldn't make the full cut with one pass from one side. Put a good 1/2" 3tpi blade on your bandsaw and you could do it in good order. Also, with a bandsaw and a jig with the leg clamped on the 12 1/2" end, you could saw it without support on the 3rd and 4th sides, something I would not do on a TS. With a stop, you could do the same with the stub taper on a BS. Maybe use the table saw to kerf for the shoulder for the stub taper. I think I would consider cutting the stub taper first.

On the jig, I think I would use a 6" or 7" X 36" piece of MDF or plywood. Install a 1/4" X 3/4" wood or metal bar on the bottom to run in the slot. Establish the angle and put an end and longitudinal stop, install a Destaco (sp?) clamp and go to work.

I would use the bandsaw even if I had a 12" table saw because it is a lot more peaceful and safe machine. You didn't mention the material, though, and if it were Oak or Eastern Maple, I might consider the 12" TS.

Donn

[david_white]

I agree with Don on how to cut the large taper but, the small taper could be done on the bot by mounting the leg vertically and having a custom taered bit made .

[david_white]

tapered bit that is.

[zeykr]

A little test drawing of machine dimensions and it looks like a jig could be made to fit the end of the shopbot to do it.


7845

Actually will need 2 jigs or 2 stations on jig as first 2 cuts the incline would be at one angle and on other 2 it would be doubled. The small end taper is to be same angle as larger one, just 1/8 deeper.

Cost will be likely higher than practical using the shopbot.

I think the 12" table saw or band saw the better approach long term. Problem is I have neither bandsaw or 12" table saw - maybe this will buy them ;-)

[magic]

I'd do it on the lathe
Make the end off-center and hire someone by the hour

[Gary Campbell]

Ken...
I like your idea for the tapers on the Bot. I would approach this using a sliding taper jig to rough cut the tapers 1/16" oversize on the table saw, then a jig as per your drawing for the Bot. Use a 2.5" surfacer climb mill to finish the large tapers, and 2 pass to cut the smaller one.
Gary

[zeykr]

Thanks everyone. I really appreciate the input!

[garyb]

Ken I think I would hit the grizzly store up the road from you and get a el cheapo bandsaw.
But if thats not an option you can also do a tapered area clear to cut them then you wouldn't need any jigs, clamp solid to stop blocks on back 12.5" and go for it.

Contact me if you would like help with the file or I will do it with you at the workshop in a couple of weeks if you have time.

[zeykr]

Thanks Gary,

A new grizzly saw is a real possibility if this works out. I thought about a tapered area clear, but figured I'd get a better finish if I tilted the leg and did a flat one.

I may try one just for test.