Reply by casual1carpenter

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Posted on Need help ripping a Hexagon post from a 4x4

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354 posts in 2445 days

#1 posted 08-26-2012 05:22 PM

QuickTooth, as the others have pointed out getting the 4×4 square and straight is your first priority. Might want to search LJ’s for “straight line rip jig”. It is my belief that you first need to get one side straight and flat, with minimal material removal. Then the second side is cut with that first cut down on the jig. Now you should have two surfaced sides that are straight and true, square to each other. Remove the jig and set your fence to the finished dimension, in your case 3.5” and set your one true square corner to the table and the fence, proceed with rip, rotate stock and make final rip.

Note that it is important that your cut angle be set precisely, you are making a large height cut and a small deviation can be a big measurement on the squared stock. Also remember that the piece you are ripping needs to be long enough to process with the table saw safely. You can site search that here to.

When you do the 60 degree cuts remember that as you remove the 60 corner you flat base to table will diminish and you need to watch that it does not try to rotate on you.

Is you TS fence tall enough to catch that hex point if your stock climbs the blade because of inadequate hold down pressure and too fast of feed? Just saying, I’ve had similar happen in the past.

With what tooling you have available this is what I would do. I have no idea however if my posting was even necessary for you, but lots of people follow threads it may be something to think about for them.

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