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Star to hang on wall.

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Project by Jim Finn posted 03-22-2015 10:55 PM 1896 views 9 times favorited 8 comments Add to Favorites Watch

I have made a number of these stars and have made two sliding jigs to make them with my table saw. One is a taper jig to make the cuts that form the five points and the other is a miter jig to cut the interior miters where the five points meet. Star is made of 1/2’ oak and walnut and the jigs are made of MDF and “T” track. The central miter joint is all end grain so it is a weak joint. I sand an angle on the back of the miter joints before assembling to form a groove on the back of each miter joint which I fill with epoxy.

-- "You may have your PHD but I have my GED and my DD 214"





8 comments so far

View Druid's profile

Druid

1560 posts in 2516 days


#1 posted 03-22-2015 11:14 PM

Looks great Jim.

-- John, British Columbia, Canada

View Dallas's profile

Dallas

3599 posts in 2208 days


#2 posted 03-22-2015 11:24 PM

Jim, when I make the smaller ones, I take a chunk of old rake handle, cut it thin and use it as a spline.
With larger ones I have used the spline and a R1 biscuit on the sides of the miter.

I don’t know if that would work for you, but it did for me.

-- Improvise.... Adapt...... Overcome!

View Jim Finn's profile

Jim Finn

2547 posts in 2643 days


#3 posted 03-23-2015 12:43 AM

Dallas I have installed splines in the past but find that what I do now to work as well and is simpler to do.

-- "You may have your PHD but I have my GED and my DD 214"

View JimInNM's profile

JimInNM

287 posts in 937 days


#4 posted 03-24-2015 11:53 AM

Your joints are perfect, the photos give the star a raised center appearance. Just wondering if it is??? Really nice workmanship and very pretty

-- JimInNM........Space Case

View Jim Finn's profile

Jim Finn

2547 posts in 2643 days


#5 posted 03-24-2015 12:48 PM

Yes it is raised about 2 ” at the center. I hope you can see this in the photo. This is accomplished by cutting the two pieces of each point on my taper jig with the table saw blade tilted at 20° The photos are of a 28” star but I am working on making four stars like this that measure 18” across.

-- "You may have your PHD but I have my GED and my DD 214"

View Jim Finn's profile

Jim Finn

2547 posts in 2643 days


#6 posted 04-28-2015 09:17 PM

I have made and sold over twenty of these stars and loose some sales because I tell the shoppers that the weather will ruin these stars in short order. Today I made a star that will endure the weather. It is 28” across and made of painted metal. I am a retired sheet metal worker so this was fun for me to fiddle with. This is my first attempt with metal.

-- "You may have your PHD but I have my GED and my DD 214"

View AstroEd's profile

AstroEd

23 posts in 96 days


#7 posted 05-29-2017 02:26 AM

Awesome.

-- I measured twice now where is my Saw?

View Jim Finn's profile

Jim Finn

2547 posts in 2643 days


#8 posted 05-29-2017 11:42 AM

AstroEd thank you. This is a two year old post and I have made minor changes to these stars: I now make the wooden ones of Cedar and Ash instead of Oak. Ash is a lighter color so there is more contrast to the Cedar and it is slightly cheaper. I now paint the same metal stars differently. (See photo) I have made 10 metal , and 10 wooden stars for this season , which starts in five days here.

-- "You may have your PHD but I have my GED and my DD 214"

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