Reply by knockknock

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

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446 posts in 2170 days

#1 posted 08-28-2012 09:59 AM

Since no one else has mentioned a ripping sequence, here is my ‘Theory’ (I no longer have a table saw to test it).

Mark one side of the 4×4 as bottom (if you want you can draw your hexagon on the ends with a flat face on the bottom of the 4×4 and points to the sides).

Set the blade to rip a 60 degree angle off of the bottom corners (30 degree tilt from vertical).

Set the fence so the blade is tilting away from the fence.

Measure the width of the 4×4, the fence should be 3/4 of the width or less from the blade (base of cut). Note: you might want to double check my high school math.

Rip the left and right bottom corners off of the 4×4.

The bottom of your 4×4 should now resemble the bottom of a hexagon. What you have established is the bottom face and the bottom left/right corners of your hexagon.

For the next 3 rips, you want to have an established corner of your hexagon, running along the fence, by always rotating one face at a time in the same direction (cork screwing the waste off, because a hexagon does not fill a square).

If your blade tilts to the left and the fence is on the right, rotate one face counter-clockwise. So the bottom right corner of your hexagon is running along the fence, and rip the next slice off.

If your blade tilts to the right and the fence is on the left, rotate one face clockwise. So that the bottom left corner of your hexagon is running along the fence, and rip the next slice off.

Continue with the next 2 rips, by rotating one face in the same direction as before, with the next corner of the hexagon riding along the fence.

Hopefully, you now have your hexagon cross section.

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