Do you own a decent jack or jointer plane? Knocking the corners off to
22-1/2 degrees shouldn't take all that long to do. Probably take less
time then setting this up on a table saw.
I have gotten two ideas in addition to my thought about using the jointer.
Rather than use double stick tape, I used a piece of 1/2" of Baltic Birch
plywood clamped to the face frame and did a few dry runs through the
jointer. With the jointer fence angled down toward the bed at a 22.5 degree
angle, the whole thing is kind of heavy and I think I will not be able to
keep the 1/2" backer board tight to the jointer fence the whole time and
multiple times as I make enough passes to remove all the material (my face
frame is oak).
An early idea was to use a 22.5 degree chamfer bit in my router table (more
on this in a second).
Then there was discussion about using a panel raising jig so that I could
make the cut with the face frame in a vertical manner so the fence to saw
blade distance is no longer an issue.
I rejected (without commenting) the chamfer bit as I really wanted to make
the cut on each of the two faces at 22.7 degrees so that the outer (visible)
edge of the joint would be nice and tight when I glued the two pieces up.
Maybe that was a silly quibble. I think the chamfer bit is the way for me
to go. As some point I will need to make a panel raising jig but I don't
have one now and the Rockler store where I can get the bit tomorrow is not
terribly far away from me.
So that is the direction I will take. Assuming my test cuts go well, I will
be in business. If not, I will own a new router bit and I will be building a
panel raising jig. Thanks all for your help. This group has almost never
failed me when I have had a problem I needed your help with.
Thanks everyone. I will report back after I have used the chamfer bit
tomorrow or Sunday!
Final report: this morning I got the 22.5 degree chamfer bit at Rockler.
Everything came out fine. Thanks to Morris Dovey for the suggestion and
thanks again to all of you for your help. I have not only completed this
step of my project successfully, I learned some other ways to solve this
kind of problem for the future.
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