How would you square this leg?

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Forum topic by sry posted 10-14-2009 08:37 PM 995 views 0 times favorited 4 replies Add to Favorites Watch
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147 posts in 3030 days

10-14-2009 08:37 PM

Topic tags/keywords: bent lamination

I’m making some bent laminated legs for a table and trying to figure out how to trim and square them once they come out of the bending form. There’s squeezeout all over them and try as I might the edges of the plies aren’t quite even. I want the final leg to have a rectangular cross section. This is the first time I’ve attempted anything like this, so I think I should poll the experts here.

Here’s where I started with a test leg:
Leg fresh from the form

And after feeding it through the bandsaw (freehand, since I don’t have any square faces to reference on the table or fence) and running it over my sanding drum here’s what I have:
Leg after rough sanding

It’s better, but the edge is a little wavy. Any ideas how to straighten that out?

Here are the tools I have available that might be useful:
Router, router table, bandsaw, drill press w/sanding drum, jigsaw
No jointer, planer, or table saw.

4 replies so far

View lew's profile


11266 posts in 3178 days

#1 posted 10-14-2009 10:32 PM

On an old New Yankee Workshop episode, I saw Norm use his oscillating Spindle Sander to thin some stock. He clamped a fence a set distance from the spinning drum and then fed the stock between the fence and the drum- against the rotation so it wouldn’t be pulled through. Maybe you could try something like that to true up the edges of your laminations.

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Dan Lyke's profile

Dan Lyke

1509 posts in 3547 days

#2 posted 10-14-2009 11:41 PM

I had a similar situation with an edge on a curved shelf I did for my office.

In my case i had the edge already glued to the shelf, but you could easily clamp the board to a surface, then…

Take the baseplate of the router off. Cut a piece of plywood that’s about a foot and a half long, and screw the router to one end of that. Screw enough spacer to the other foot of that board to hold the router up above your edge piece. This way the router is on a part of its baseplate that overhangs, so you can have the router bit a fixed distance above the flat surface you’re moving the router on.

Put a straight bit in the router, and use that assembly to have your spacer run along the surface you’ve got the leg clamped to so the router takes off that wavy edge. Flip the leg, adjust the router just a little bit down, do it again.

If this isn’t clear, holler and I’ll either do some drawings or put my setup back together and take some pictures. Alternate router bases are awesome!

-- Dan Lyke, Petaluma California,

View bob1638's profile


17 posts in 2571 days

#3 posted 10-15-2009 01:09 AM

If you have a jointer…you could clean up the sides…then run it thru the table saw for final dimension.


View sry's profile


147 posts in 3030 days

#4 posted 10-15-2009 04:31 PM

Lew – Good idea. I was thought about something similar but couldn’t decide how to actually implement it

Dan – it took me a minute to realize what you were trying to say, but I think I got it now (similar concept to the router sleds for surfacing a large slab, just a different setup on a smaller scale, right?). Sounds like an excellent “plan B” if the drum sander doesn’t work out so well

Or maybe I’ll just pick up a belt sander and do it that way

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