need to cut about 200 pickets… each has a double point at the top (like these: http://www.history.org/publications/books/images/wmsbgglgardens.jpg) - how would you do the valley cut in the center? would you do 5-6 at a time on the bandsaw, line them all up end to end and use a circular saw?
the pickets are 40×6 x 3/4 inches, they will have a double point at the top, like an upside down "W"
I'd probably cut single pickets from 1X3s and hold two together with the horizontal rails. That appears to be how they were done in the link/picture you provided.
Thanks for your replies so far - I keep picturing lining them all up and cutting the valley along the top with a circular saw, then I can get large batches at one, and I can follow up with the miter saw to quickly clip the corners.
Ellen I like the sabersaw/jig idea, might be a good excuse to finally get a good saber
Gene they are single boards, the one on the right in the pic is slightly split which makes it look like two. I want single boards. There are several fences just like this in Colonial Williamsburg, and while they may not be the most practical, I want an authentic look (i.e. it's what the wife wants!)
yes to the above ,
or you could make a jig for the router and use a spiral cutter and bushing to follow it,
any way you decide , it is patience and repetition .
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why not tilt your tablesaw blade to 45 degrees and clamp a few of these boards (however many you can comforatbly support) and slide them accross the blad with a mitreing jig. Flip and repeat. Then you've got a whole bunch done quickly and in an easy to repeat fashion? not sure if you have a crosscut sled or tablesaw capable of handling the length of the stock though.
I like a tablesaw solution best providing you can stand them vertical. I would clamp a bunch together. Two of the angles are the same from each edge. You can register the first edge against a spacer when you do the first cut, then remove the spacer and run it through again registering the same edge to cut the 2nd angled in the same direction. Then register the other edge again with the spacer inserted and do the same procedure again. Of course the blade will be set at 45 degrees.
Hope this is a little clearer than mud. Don't hesitate to ask for clarification if your interested in this method. This is the same solution as bently but with the addition of the spacer.
Don't see why not Ellen. A bunch clamped together should be plenty stable. The pickets would have their top edge on the table with the width of the picket 90 degrees to the fence. I would make some trial cuts first to ensure accuracy, but once set up it should go great. you might want a scrap piece on the back to prevent tear out on the last piece.
You know if you do the cutting outside and as people walk past you might be able to get them to do it because its soooo much fun and maybe even get a frog, kite and broken jack knife…
All kidding aside, The clamping many together and using your table saw would be the quickest if you are safe. All clamped up your might be able to do 25 or more at once… Be safe though.
I'd do them one at a time I think thats the only way to get good or perfect results possibly with a Handsaw boring answer sorry but how big can one fence be ? So it might take a while how long does the fence need to last? If you get inconsistant results it will look dreadful . When you have so many side by side any small flaw will be instantly recognisable .Alistair
If the cuts were to be at a 45, they would only be about 2" deep. The hypotenuse is slightly less than 3". Even so, a 7" circular saw will not cut any near that. a 10" Table saw should come close.
Rethinkning this, I think I'd set up a jig on the band saw. Like it has been said, more precision and if they are off, it will be very distracting, especially 2 on the same picket.
How about a jig for a jigsaw, and slam them in the field while you put them up. Less handling and it should not take too long to cut each board as you go down the line.
make a jig /guide for the bandsaw and gang clamp a bunch at a time. You will be done in no time.
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