Once the blank has the layout lines drawn, it is time to cut the slots for the ellipses.

The first step is to set the blade height. When the cut is made, there should be about 1/16" to 1/8†of material left holding the two sides together.

By not cutting through the blank it keeps the pieces aligned during the glue up stage

Set the blank on the jig and adjust the angle and the end stop so that the front SHORTER layout line is positioned to the LEFT side of the blade cut. Orientation is when you are standing at the back of the saw looking forward. (These pictures are from the SIDES of the saw).

 

 

Front of cut located

 

Continue to adjust the angle and the end stop so that the rear LONGER layout line is positioned to the LEFT side of the blade cut.

 

Securely tighten all adjustments. Once these angles/lengths are set, they will not change for all of the remaining cuts.

Clamp the blank firmly in the jig. Double check the layout lines.

In order to keep the correct orientation of the blank, I labeled the end of the blank nearest me.

 

With everything secure, make the first cut.

In the front

 

Out of the rear

 

Unclamp the blank.

To make the second cut, I made a space strip to reposition the blank without having to change any of the jig setting. My first guess was that this spacer would be 3/8†thick- the same as the width of the finished cut. BUT that was too thick. I guess there is a way to calculate the thickness but trial and error won out. It came out closer to 1/4†(.265â€).

 

 

 

 

 

The second cut, to widen the slot, is made with the blank position so that the front LONGER layout line is on the RIGHT side of the saw cut.

 

The rear SHORTER layout line is on the RIGHT side of the saw cut.

The walnut spacer strip can be seen between the blank and the fence of the jig. The thickness of the spacer strip could be different for each person. So check the setup carefully. Also, Make sure the blank butts up against the end stop before each cut.

 

Complete the second cut

 

 

 

After the second cut has been made, there may be a thin piece of material left in the slot. I made another spacer- about 1/8â€- substituted it for the original spacer and made a third “clean out†pass.

The finished cut should be 3/8†wide and almost through the blank.

 

 

 

Part 4 will cover the first glue up and trim of the first set of inserts.

 

Awesome Lew! I am so glad to see this series back up!

Just shared all three on our facebook page Lew, https://www.facebook.com/pages/The-Patriot-Woodworker/159966080737021?ref=hl

Well get this series in our newsletter too.