Easy solution for cutting the horn panels on the WH10
Posted: Thu Apr 14, 2011 8:54 pm
I’d heard that the Wedgehorn10s were a tough build. After cracking open the plans I could see why. The horn side panels are beveled on 3 sides while angled on two. It’s the two angled sides that require a compound miter cut.
At first look, I thought I was going to have to use a circular saw with crosscut sled. But, I really didn’t want to screw up my sled with the angled cuts and I abhor using a circular saw with a perfectly good table saw available. After cogitating a while, this solution worked really well and actually was very easy. I cut 6 side panels, 3 top panels, and 3 bottom panels in about 45 minutes.
First, make sure that you draw your panels as mirror images. You need the cut lines to show.
Since the front and back of the Side Panels are parallel, go ahead and make these cuts.
For the top and bottom of the side panels, use a piece of scrap plywood to serve as a sled. Set the blade to the proper angle. Line up your cut lines to the edge of the sled (you’ve already run this through the saw to make sure it is parallel to the fence). Take two scraps and tack them with a brad nailer snug up against the two edges with a half an inch or so hanging out over the edge. Move the fence over a little and run the sled through the saw so that you just cut the protrusions. This cuts the protrusions to proper angle.
Now replace the panel and line it up to the edge of the protrusions. Make the same cut on all of the panels if you are building multiple cabs.
At first look, I thought I was going to have to use a circular saw with crosscut sled. But, I really didn’t want to screw up my sled with the angled cuts and I abhor using a circular saw with a perfectly good table saw available. After cogitating a while, this solution worked really well and actually was very easy. I cut 6 side panels, 3 top panels, and 3 bottom panels in about 45 minutes.
First, make sure that you draw your panels as mirror images. You need the cut lines to show.
Since the front and back of the Side Panels are parallel, go ahead and make these cuts.
For the top and bottom of the side panels, use a piece of scrap plywood to serve as a sled. Set the blade to the proper angle. Line up your cut lines to the edge of the sled (you’ve already run this through the saw to make sure it is parallel to the fence). Take two scraps and tack them with a brad nailer snug up against the two edges with a half an inch or so hanging out over the edge. Move the fence over a little and run the sled through the saw so that you just cut the protrusions. This cuts the protrusions to proper angle.
Now replace the panel and line it up to the edge of the protrusions. Make the same cut on all of the panels if you are building multiple cabs.