I would like to start out by saying the projects listed on this site really show some of the best talent and creative
minds ever amassed on one website. Makes me jealous. Any way I have been asked to show how I make a Texas Star, so I decided to share this with everyone.
There are a few things you need to make before starting. First thing is to make a pattern making fence for your table saw. It is real simple. I usually make mine 4-6 inches wide out of 3/4”plywood. Rip a scrap piece of plywood 24” long what-ever width you want plus saw-kerf. If you go 4” make it 4 1/8 rip to allow for kerf. Clamp to fence
and set fence for 4”. The fence should now be even with outside of blade as shown in fig.1
Templates for Star should look like this:
Another view put together:
Next we need to prepare material. I glued up a piece of maple and walnut (1 1/2” thick x 2” wide). Joint edges and glue together.
After glue up cut pieces about 1” longer than patterns. Lay patterns on back side of blanks pin in the center with 1 1/4” nails. Stay away from ends an inch or so. Make sure to orientate all blocks the same. Fence on saw needs to be 1 3/4” above table using 1 1/2” material. Use saw to flush cut pieces as shown in pics.
Wide fence will keep drop offs from kicking out.
Do all five the same, should look like this.
Next build a sled with 30 degree bevel, leave small shoulder on bottom to rest piece on for beveling. I built sled wide then ripped it so it would be right on the blade. Place pieces on sled with rh. stop and lh. stop as in pic.
After doing all sides you should be ready for glue up. Place one leg on flat surface nail stop on both sides. Go to next leg line up and install stops. Leave last leg free so you can wedge together as shown.
Hope this helps those who tried to do these the hard way.
Top Circle Moulding-Millworks.
P.S. Save all patterns for next Star. If you don’t move fence you can go back and do another with out changing set up, unclamp temparary fence when using sled.
-- Medicaid Carpenter