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Help with a mantle

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Forum topic by David1982 posted 05-28-2015 03:54 AM 733 views 0 times favorited 10 replies Add to Favorites Watch
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David1982

5 posts in 958 days


05-28-2015 03:54 AM

Im going to be making a mantle to sit over top of the current mantle on my fireplace. It will be a 8” x 10” beam 7’ long that I want to cut a large rabbet into. 6 1/2” x 6 1/4”. Im just getting back into woodworking and I need help. I don’t want the rabbet to extend all the way to the edges of the beam. I want it inset 3” from either end so as to hide the cut from the side. My problem is my table saw won’t cut deep enough, and I’m unsure of how to finish the cut on the inside corner of the rabbet. I tried attaching some photos, hope they load. If anyone can give me some advise I would appreciate it. I can email the photos of what I’m trying to do if they didn’t load here. You can also reach me at davidthompson1982@gmail.com

Thanks guys in advance for the advise.

David


10 replies so far

View esmthin's profile

esmthin

77 posts in 647 days


#1 posted 05-28-2015 04:59 AM

The only thing I can think of is to cut what you can with the table saw, then finish the rest with a chisel. That’s what I would do.

-- Ethan, https://instagram.com/ethan_woodworker/

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David1982

5 posts in 958 days


#2 posted 05-28-2015 01:13 PM

That would be fine, however my ts only cuts to a depth of 3 1/4”. The two cuts I need to make are 6 1/2” and 6 1/4”.

View Bill White's profile (online now)

Bill White

4456 posts in 3426 days


#3 posted 05-28-2015 02:04 PM

Router and chisels.
Bill

-- bill@magraphics.us

View TheFridge's profile

TheFridge

5765 posts in 952 days


#4 posted 05-28-2015 02:22 PM

use a table saw to cut an inch of depth at a time on each side and a multi tool to finish the saw cuts and cut the ends to release the waste piece. I say only an inch at a time because a multi tool has only so much reach with its blade.

Once you get to where you only have a 1/4” or so left the. Make your final cut with your table saw, be careful with the multi tool, and use a wide chisel to clean up the rest.

I’d prob make a spline cutting jig to crosscut the ends clean then finish up with a chisel.

-- Shooting down the walls of heartache. Bang bang. I am. The warrior.

View Kazooman's profile

Kazooman

628 posts in 1418 days


#5 posted 05-28-2015 03:15 PM

I have a thought on how to do this, but it is potentially dangerous. So…... Don’t this on my say so, but it might jog someone else’s thoughts for a safer solution.

Use your table saw or a good circular saw to make the cuts as deep as you can right up to your layout lines. This will give you clean edges where the ends and front of the piece meet the existing mantel. Then CAREFULLY cut inside these lines to the required depth with a small chain saw. The bulk of the waste should pop right out. Then clean up the interior with a chisel. It will never show so it doesn’t have to be perfect. The clean edges from the table saw cut will keep the piece in place with no problems.

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Daruc

459 posts in 598 days


#6 posted 05-28-2015 03:18 PM

I would do it with a sawzall.

-- -

View madts's profile

madts

1685 posts in 1806 days


#7 posted 05-28-2015 05:50 PM

Make it out of 4 pieces of wood, all with 45 deg. angles. If done right it will look like one piece of wood.

Madts.

-- Thor and Odin are still the greatest of Gods.

View jerryminer's profile

jerryminer

528 posts in 907 days


#8 posted 05-28-2015 06:22 PM

Looks like a chainsaw project to me. Tablesaw and router won’t even get close.

If it were me, I’d cut close with a chainsaw, breaking out chunks as I went, then finish with an angle grinder with a carving disk, and probably a chisel to clean out the inside corners.

View pintodeluxe's profile

pintodeluxe

4859 posts in 2279 days


#9 posted 05-28-2015 07:16 PM

You can make a built-up beam, and either miter the corners or else cover the glue lines with a thin veneer piece of matching lumber. That way the TS will be able to make the cut with a 8” dado set.

This Mantel beam is a glueup of 4 pieces, and even up close I can’t see the jointlines.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

View BinghamtonEd's profile

BinghamtonEd

2281 posts in 1835 days


#10 posted 05-28-2015 07:39 PM

I second the opinion of making it out of more manageable pieces. I wouldn’t attempt to do that on a table saw. That’s about 47 board feet of material, assume its dry and comes in around 4lb per board foot, that’s almost 200 lbs. If you already have the wood, I agree with roughing it out with a chainsaw, and then cleaning it up with chisels.

-- - The mightiest oak in the forest is just a little nut that held its ground.

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