THIS has proven to be a challenge. I’m currently unemployed, so buying tools is just about out of the question. (The occasional pine board maybe. But even that is pushing it.)
I’ve got a box in my head and wanted to use mitered joints. This got me Yak Shaving in to creating jigs and the like.
But I got stuck on the fact that I don’t have a reasonable 45 degree reference angle. Nothing I can use to clamp a workpiece down to my table saw sled.
MAYBE my table saw cuts a precise 45 degree angle when I’ve yanked it in to position and tried to hold it there while tightening it back down. And MAYbe my harbor freight chop saw cuts a precision 45 degree angle. But neither of them are capable of creating a long enough cut that errors within the tolerance I’m looking for will be exposed. So they’re really both out. (Though I suppose I could cut 8 or 9 pieces, then stack them and see if the resulting triangle has two equal sides. But the margin for error in that process is really high.)
SO I started thinking… How would I create one that was within sufficient tolerance for cutting long miters?
I can cut something square, so I started there with a piece of 3/4” birch ply. Then I thought: “Well, if I position it ‘corner to corner’ along the kerf line of my table saw sled and clamped it down, then I could be sure I was cutting along the right angle.” I went through rather a lot of plywood trying to keep that positioning stable. No matter how close I got, I was still off by enough that it bothered me. (As determined by the component pieces not matching up.)
I’ve got a couple ideas kicking around in my sick little mad scientist head. But they get weirder and weirder as I get more and more frustrated.
Once you have one, (say, out of a piece of ply) you can make any number for any thickness, etc.
How would you do it? No protractor and no 45 degree square kicking around.