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Artisan Carpentry
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Discussion Starter · #1 ·
So yesterday I did some router table millwork... today was the table saws turn. I milled up 126' of 5" stepped casing for a Victorian. This job will related to several threads as this casing will be Jack-Mitered and Backbanded and will have a cabinet head crown too.

This casing was made with one pass on the table saw, followed by a router table pass, and then 3 passes through the table saw on edge. Tomorrow I will ease the corners on the steps with a sanding and will hog out a relief cut on the back of the casing with the dado head.
 

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Artisan Carpentry
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Discussion Starter · #3 ·
more please:thumbup:
Otay.

The smooth faces on the steps have not been sanded. I used a Freud Glueline Rip blade it produces very smooth cuts... great for this millwork application. The blade produces ribbons like this that are paper thin and uber-smooth. Also here is a pic with a couple of steps cut and one of the pile ready for easing of the step corners.

I'll check in later... off on a bike ride.:scooter:
 

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Maker of fine kindling
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Nise set up, Bass:thumbup:

Sure will suck if you are few feet short though.:laughing:
 

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Maker of Fine Sawdust
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I cut it three times and it's still to short :laughing:
 

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Cost my some more mony!!!!

Another new saw blade,3 dozen spring clamps--:laughing::laughing::laughing::laughing:

Can I order all these toys through you so you get the commission?:thumbup:
 

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Maker of Fine Sawdust
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Stop using the 1" mark for your exact measurements. Use the 10" line, if you screw up by 10" you deserve to have to remake it. :laughing:
 

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Artisan Carpentry
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Discussion Starter · #15 ·
Nice work Bass... You'd give Norm a serious run for his money. :thumbsup:
Thanks Chris, I like Norm.:thumbsup:

Here are a couple of pics of the "relief cut" set-up... I was dialing in the layout and depth... the shallower cut (3/32") is what I went with. It took 4 passes, but only two set-ups--run--flip end for end and rerun--move fence 3/4"--repeat. Making these shallow and wide dados in this set of millwork took one hour.
 

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Artisan Carpentry
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Discussion Starter · #16 ·
Another new saw blade,3 dozen spring clamps--:laughing::laughing::laughing::laughing:

Can I order all these toys through you so you get the commission?:thumbup:
Mike the clamps and the Glueline Rip blades are worth the money... I wish I got a commission on the few products I recommend... I need to get my own website and start getting some ads on there. I spend enough time sharing ideas... would be nice to get something for it somehow.

The good blade helps, but the featherboards are the key. A few times I failed to keep the boards tight to the table and got bumps in the step line. I re-ran and couple that I noticed, but this one I missed and the saw was switched to the dado head... so I got out my straight-edge and utility knife and just fixed it... took just a few seconds to shave it back to the line:
 

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Maker of Fine Sawdust
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How much time you got into them moldings Bass? A 2 1/2" cutter for my W&H costs about $80 and you could run a 10' length in about 1 minute the way I have it setup.
 

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Artisan Carpentry
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Discussion Starter · #18 ·
How much time you got into them moldings Bass? A 2 1/2" cutter for my W&H costs about $80 and you could run a 10' length in about 1 minute the way I have it setup.
1 hour ripping random lumber to 4-3/4"
1 hour set-up
4 hours milling faces
1 hour plowing out backs
3 hours sanding, etc.

10 hours total x $60/hr = $600 labor
Material: = $150 wood
Total: $750 or 5.95/lf for custom 5" casing... seems fair to me.:blink:

I think the mill wanted a couple hundred for knives and set up and it was going the be a wash so I just did it... work being scarce and all... or so I hear. For any larger run than this a shaper and power feed or W&H would be nice... but you know me... I still used a folding rule today.:jester:
 

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Maker of Fine Sawdust
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$80 for cutters
$150 for wood add 15% $173
1 hour to size blanks $
1 hour to hog out back $
$1.69/lf to run using my formula (125') $211 about 15 minutes to run.
1 hour to sand, maybe $

$465.00 using 3 hours 15 minutes time.

$3.72/ft

But of course that doesn't include the W&H setup which is about $2500

Usually if I am running mote than 50' of something I want to make a W&H cutter.
 
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