I have a dilemma

You need a sled for the table saw and then only need to square one end. After you’ve sliced all the pieces, the last piece will be left over and most likely trash…

Here's a pic of my sled that Patron took when he came for a visit. It’s a couple of pics down…

-- Childress Woodworks

I advise you not to be too quick to dismiss the straight edge and a circular saw idea. I’ve used this approach on several important cuts that I could not handle on another saw in my shop.

In the interest of full disclosure, I now often use a festool plunge saw and a festool track (which is great) but earlier I used a normal straight edge and conventional circular saw with acceptable results.

Don’t set the depth of the circular saw any deeper than necessary. In my experience, a cordless (DeWalt) circular saw goes slower (much slower) but it seems to give a smoother, cleaner cut and I really like having the blade on the left side of the saw. Whatever you do, a sharp blade is essential.

-- Rich, Cedar Rapids, IA - I'm a woodworker. I don't create beauty, I reveal it.

I just came up from the shop about an hour ago working on some end grain boards myself. I use my table saw with a Freud combo blade (glass smooth cuts). I set the fence at the desired width and used my Incra miter with a straight jointed/planed board screwed to it coming to within 1/4 inch of the blade at a 90 degree angle. Push the cutting board through using a push stick on the side between the fence and blade.

I usually like to have the off feed to the left of the blade but this method worked fine as long as the saw is tuned and the fence is setup correctly. Use a scrap piece of wood to supply mild pressure to the left of the board as you get closer to the blade to keep your hands away. Follow through completely and pull the glue up away from the blade when you pull back for the next cut.

-- Mike.... West Virginia. "Man is a tool using animal. Without tools he is nothing, with tools he is all.". T Carlyle

A straightedge and flushtrim bit on your router will work. It’s a great cleanup method after using the circ or jigsaw to get close.

-- Optimists are usually disappointed. Pessimists are either right or pleasantly surprised. I tend to be a disappointed pessimist.

Keep your cuts a little on the thick side. When you glue up the next direction, glued joints can move. If the thickness is a little long, the finished product, when smoothed down, will be right. It is better to have a chopping block too thick than too thin. —Just a thought

-- David in Damascus, MD

Hey bentlyj, are you in Vegas? I’d love to come by your shop some time if nothing else just to say howdy.

-- "Courage is being scared to death -- but saddling up anyway."

OK, I used a straight edge and a circular saw. I got it square and then I sliced it with my band saw.
Re-gluded, sanded it flat with my drum sander today and then I rounded over the edges, made finger holes and started the finishing process. I’m using Watco butcher block oil. Once it’s done I’ll post pics.
Thanks to all who responded with tips I appreciate it. I now know why these things sell for $85 to $100. They are a pain to make. This first one isn’t sellable but my wife will love it. I learned a lot. What to do and what not to do. That’s why I love working the wood. I learn new things all the time.

-- "Courage is being scared to death -- but saddling up anyway."

Someone once told me that the first 3 or 4 of anything are just to tell you what you are doing wrong. Once you have it figured out, try making 3 or more – exactly the same. That is where the challenge begins.

Someone else once told me that when you make something with a drawer in it, make the drawer first, make everything else to fit the drawer. He told me he would never make the drawer last and that it is impossible to hand make a drawer to fit a predetermined hole. I hope he never does a kitchen or chest of drawers.

There is always something to keep you challenged and thinking – if you allow it. Good job!

-- David in Damascus, MD

Well, it’s done. Like I said it’s not perfect but my wife loves it.

-- "Courage is being scared to death -- but saddling up anyway."