So how do I do this ?

A jig and the router table would seem the safest way in my mind. That’s an interesting cut. Personally, I try to avoid those. ;-)

-- Working at Woodworking http://www.VillageLaneFurniture.com

I wouldn’t use the table saw… that looks a little too crazy for that.

I think I would make a simple little jig to safely do this on the router table. Take an extra piece of wood as tall as what your leg is, and twice as wide. I would cut one end at 45 degrees. If you put double stick carpet tape on that 45 degree bevel cut on your jig, then you could stick the side of your leg to it and use a wide rabbet bit on the router table. It would cause your leg to ride on the table on its point (the far right point that is dark black in your pic above). In your pic above, the taped bevel jig would attach to the side of your leg that you can’t see.

Put a wide rabbet bit in the table and hog out a little at a time. Since the leg will be rotated 45 degrees on the table, you are technically making a rabbited 90 degree pass, instead of a 45 degree V-groove. When you have it all hogged out, use the smallest rabbet bit for the very bottom to minimize your chiseling, then just chisel out the corner.

Steve

-- As iron sharpens iron, so one man sharpens another. (Proverbs 27:17) †

Zuki,
I agree with the router table as being safer. How bout a large v-grove bit, just take a little at a time and only have to chisel the rounded end.
BTKS

-- "Man's ingenuity has outrun his intelligence" (Joseph Wood Krutch)

Pat – you are first off the block recommending the router table and jig

Russel – #2, and I’m trying something a little different

Dave – who is Jojo ? Unfortunately I have the legs roughed out.

Steve – #3. I see what you are getting at. Rabbet bit is indeed another option.

BTKS – #4, hmmmm v-grove.

Bently – its a one piece

Survey says . . . jig and router table with chisel cleanup. I just have to figure out which bit(s).

PS – I just sharpened all my chisels with my new WS3000 and I’m looking for excuses to use them. Boy are they sharp. :-D

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Zuki, have you made your cut yet?

-- As iron sharpens iron, so one man sharpens another. (Proverbs 27:17) †

I’d go with a 45 deg cut on the table saw. Then glue in the piece that needs to be put in below the red.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

How about something like a Fein multimaster with a straight blade? If you mark the depth, you could repeatedly cut along a line to that depth. It’s pretty good at cutting into large pieces and making notches and grooves.

-- Rich, Seattle, WA

I agree with Karson, Table saw and glue back the cut off. My guess is you will never see it.

cut it separate and than dowel it back on with some good glue. You also can reattach it with a mortise and tenon for more strength

-- making sawdust....

I also agree with Karson’s method.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1

Heres my take on this. I just sketched it out. You wouldn’t have much waste to chisel out
Hope it makes sense
You can cut a rip and stop cut it on a router table with a 3/8 or 1/2 spiral bit. If you use two fences you have to come from two directions.
Or you make up a jig and then you can come form the same direction
I would try on some scraps with small cuts at first

Lookin at it some more I reckon you could use one wide bit and use small cuts and only use one fence. different possiblities

-- If you have a garden, a shop and a library, you have everything you need with apologies to Marcus Tullius Cicero

I like the router method. Something similar to what TNWoodwright sketched out, only I think I would somehow attach the leg to a jig/sled with the 45 degree angle built into it. Make the sled wide enough to have a couple of good and safe places to put your hands as you push it through.

Just my 2 cents worth. :)

-- Dennis, http://www.maplegrovewoodworks.com/ http://twitter.com/#!/MpleGrvWoodwrks

Now your talkin!!

-- If you have a garden, a shop and a library, you have everything you need with apologies to Marcus Tullius Cicero

not sure exactly what tools you have to work with , but there are other ways than those mentioned above.
you could saw the entire leg in half lengthwise. make the two stopped 45degree cuts. then glue the leg back together with a nice piece of veneer or accent wood in between to make up the saw kerf.

the other method would be to cut the joint entirely by hand. think of it as a really long sliding dovetail.
saw out your outside edges of the joint as far as you can . then pare the rest away with chisels and guideblock.

good luck with whatever you decide, looking forward to seeing this project posted.

-- Junior -Quality is never an accident-it is the reward for the effort involved.

Choices Choices.

I have not made the cut yet. I will be getting at it this weekend (hopefully)

Thanks for the sketches and diagrams guys . . . gives me more to think about.

Im gonna have to take pics and post what I do. I’m still partial to the router idea.

The leg is actually 1 1/8

Interesting idea JJ.

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