Building an octogon tray, the size of the handles dictates the needed size of the octogon shape, the inside tray, is around 20-1/2” from flat to flat, a big tray.
Here are the handles made, they have a 8 deg. miter, to splay the side pieces,
however, I want to fasten the handles to the face side of the tray, unlike the other one where the handle was assembled with a top and bottom rail, this style of handle will not have a bottom rail, due to direct connection to a side piece of the tray, to account for the bottom rail.
The angle of incline will be at 45deg. , just as the other style handle.
Now with this in mind, I would need to cut a compound miter, with the saw tilted to 45 deg., and the miter at the 8 deg..
I don’t have a (compound miter) saw, I have a 1980’s craftsman miter saw, I do have a 1970’s radial arm saw, which I could do compound miters on, however, the swing for the miter at 8 deg. may not be repeatable from one side to the other.
I have three options, build a jig to either fit my miter saw, radial saw, or table saw.
I looked into the miter saw, but the motor would get in the way and I would need two jigs for a left and right miter.
A jig for my radial saw, would work fine, but thats a lot of extension to pull the saw through, around 8” plus the width of the jig, it could be close to around 10” or 11” before its all done, thats to far to pull the saw through a workpiece that will be jigged up,
The best option is build a table saw jig, dedicated only for this style and size of handle (workpiece).
The jig is made to give a splay of 8 deg. mitered at the top rail and the top of the 2 sides,, the 2 sides are mitered at 8 deg. to fit as a butt joint to the face of the top rail, the top rail is mitered at its very top edge to continue the flow of the angle of splay visually only.
here is the jig unloaded,
The jig also allows me to line up my dowel centers when building the handles.
Here is the workpiece, (handle) ready to be jigged up.
Here is the workpiece ready to be compounded mitered, the jig holds the workpiece at a 45 deg. angle of incline, while the sides are already at there spayed angle of 8 deg.,
the mitering operation on the table saw,
The blade stays at 90 (0) on the saw setting, and the back of the jig rides against the saws fence.
and the results of the compound miter,
and a mockup of how it will be assembled to the side of the tray workpieces.
The rest is a sequential tasks of building the tray itself, by cutting the tray sides, routing rabbets, and cutting the 22-1/2 deg. miters, and finally assembly, glued up and small brad nailing.
for the inside bottom, I used old 3/4” shelf boards badly warped, a lot of face jointing, and thickness planing, then cut to a finish width of 5-1/2”, then finally resawed on the table saw, to make 5/16” thick planks, then a quick skim in the thickness planer.
Now I will start cutting to fit the planks, because my octogon side pieces are not perfectly made, so variations in the frame, requires me to scribe each plank to fit the octogon frame.
That’s all for now, I’m in between tasks, so it will be a little bit before I can continue this project.
Have fun in the shop.