The more I worked on this project, the more I recognized that straight, square lines were critical to the look of the finished piece. I normally like to round-off edges, even just a bit, to to soften them, and because paint and varnish are most likely to crack on sharp edges.
But the look of this cover seemed to depend on nice, crisp lines. I had to saw the ends of the strips off squarely, so they'd be perfectly flush with the sides.
But how? Every time I'd tried to saw something -- like screw plugs, for instance -- flush, the saw teeth had scratched the surface all around. I certainly didn't want to do that with this piece.
|Strips need to be trimmed flush|
On most saws, the teeth are bent outwards slightly, alternating to the right and left. This 'set', helps the saw make a cut that is wider than the saw, so the saw blade doesn't get stuck in the cut.
The teeth on flush-cut saws are not set, so -- theoretically, anyway -- when the blade lies flat on wood, the teeth don't dig or cut into it.
There are expensive furniture-making flush-cut saws, but Japanese style flush cutters are now popular and relatively inexpensive, so that's what I opted for:
|The tool of the job: flush cut saw|
I also didn't try to cut the ends exactly flush... I left about 1/32" of wood protruding from the end... just enough to give the saw teeth a bit of breathing room.
|Saw in action. Tape prevents even little scratches.|
|Finished with random orbit sander|
|After a complete sanding... looking pretty good!|
|With a coat of linseed oil.|
|Installed in piano studio|
|Center post trimmed|
Next Episode: Cutting Boards