|Project by USCJeff||posted 10-04-2011 04:35 PM||5203 views||2 times favorited||4 comments|
While this is a somewhat of a construction project, I’m calling it woodworking since all the materials were derived using woodworking steps. There are several commercial jigs now for doing this on a table saw, but It is really fairly simple to build the jig or simply use secured straight edges. *I would note that while I can’t prove it, I figured this process would be murder on a high quality blade, so I used a simple $10 blade. I might not be needed, but I’m thinking it would dull the blade very fast in a manner not consistent with it’s design.
The first two pics show the installed end product. Pics 3 and 4 show the starting 2×4 studs and then the re-sawed pics of the studs. Pic 5 is a crude mock setup. Use longer straight edges with both sides clamped firmly. Just threw this together to get the general idea out there. The last pic is a terrible sander purchase that finally helped a bit. The contoured attachment worked very well to take out the blade ridges left.
Ok so the method isn’t too tough. The angle of the board being fed is determined by what the cove will look like. Since mine is symmetrical, a 90 degree feed was used (several calculators on the web if needed). Go little by little on the blade height. A stiffener wouldn’t hurt either. The edges have a couple of 45 degree rips that installs it flush to the wall and ceiling. The sanding was the downside. There is really no way to create the molding without having to sand a lot of saw marks. That took some time. Several coats of primer and a higher gloss paint were used after some extensive nail filling and caulking.
It took a long time start to finish. Buying the molding cuts a lot of time, but where’s the fun in that? I’d estimate the studs used cost less than $10. The other stuff was on hand, so it was very very cheap compared to the per foot prices of the store bought stuff.
-- Jeff, South Carolina