I need to make 4 fairly identical legs to replace legs chewed on by a pair of dogs. We are well past the young dog chewing stage now and I wanted to rescue the coffee table.
I was planning on replacing the tapered legs with just 2"x2" square legs but my wife would prefer the taper. I should be able to do this, I was thinking a very fine tooth blade for the Band Saw at high speed might be best but was hoping for some input for those with more experience.
The legs are 16" long and the taper is 2 sides for about a 12" length.
I have available for use the following options:
12" Band Saw
Radial Arm saw
Chop Saw
Scroll Saw
Jig Saw
Circular saws
Draw Knives
Belt Sander
Palm Sanders
Planes
band saw is the best for speed, control and safety. Scroll saw and jig saw also have good control and safety though you would need to go very slow. a circular table saw would work with a tapering jig and a push stick.
I would have to play with it, but I think the radial arm saw would do the job.
Attach a wedge to the table that holds the leg at the correct angle.
Then make you first cut turn the leg 90 degrees and make your 2nd cut. Repeat on the other legs.
Resetup and cut the last two sides.
IANA woodworker so I could be all wet here.
A fine blade is not necessary as what you’re doing is mostly a rip cut. I’d make your decision more on the width of the blade. A wider blade with give you a better cut.
I wouldn’t think a band saw would be a very good tool for the job, unless you have a good jig set up to allow a smooth, linear cut. Band saws are for curves.
Table saw and tapering jig(s). Once the jig is made it should go pretty quick.
Surely with all that selection of tools there is a table saw? If not I guess the radial arm saw and a fence and clamp.
One alternative is to just buy ready-made table legs. I just checked Lowes and Home Depot’s websites and both sell table legs in various lengths and styles for under ten bucks each.
Unless the radial-arm can be pulled out and set to a 90-degree cut. Some can, making it sort of an upside-down table saw. Then, set up the stock on a wedge and slide it along the fence to get a straight cut.
The belt sander will finish the job well, as will the plane for a traditionalist.
If you only have one saw in your arsenal the band saw is the best tool you can get. With a good selection of blades you can make any type of cut necessary.
Those tape jigs are nice if you are changing up angles for one time projects, I guess. At the furniture shop I worked at, they went the high tech expensive route. They had a jig for each taper they needed that consisted of a block of wood glued to a long piece of wood.
I would use the bandsaw and cut the taper to about 1/16" from the layout taper line. The type of blade and speed is not critical because you will clean the cuts with a handplane before final sanding.
Of course, once you cut the taper on one side and flip it 180 deg., then the angle will not be the same - you are pushing a tapered edge against the side of the jig, not a square edge. adjust accordingly.
“I’ve cut the darned thing 3 times and it’s still too small…”
I typically cut my tapers on the tablesaw, but I have cut them with a handsaw, bandsaw, even hacked one out with a scrub plane but always cleaned up with hand planes. First a jack to get close to the line, flat with a jointer followed by the smoother after the joinery is cut.
First leg tapered successfully after a new blade and a band saw overhaul. Adjusted and checked right angles on everything. I do the next three legs tomorrow I hope.
