Thinking in 3D

Close, yet not good enough.

My relatively new Cobalt 10″ table saw’s adjustment gearing pinion is somehow jammed and so at about 42° is pops back to 40° and will not set the saw blade to a requisite 45° angle. The 45° cut is essential for making the custom crown molding stock from New Zealand pine 1″x4″ lumber.

If I could have made the crown molding lumber pieces, I could have subsequently mitered and installed finish pieces that I’d I drafted up a plan for this morning and then installed them as the finish molding millwork elements. And, then, everything would have been ready for joint compound, sanding and paint.

I also used 4″x4″‘s, grip clamps and pipe clamps to glue together a mahogany laminate butcher block from joiner and planer milled mahogany 1&1/2″ x 1&1/2″ African mahogany from Parkerville Lumber in Manchester near Manchester Glass.
Then I installed the mahogany countertop by making a precision template from 1/4″ plywood and then using the precision template to scribe transfer the specific custom dimensions onto the rough milled block laminate so my finish cuts made for a perfect fit.
I fondly recall nervously bringing the finish countertop up from the shop and being thrilled by the way it shimmied and shook as it slid down into perfect position.

Returning to today, however, and now that productivity has turned back to planning; I am postulative regarding ideas for further millwork. I am thinking that during another job I could also clamp diagonal board fences to the table saw during the milling process and run a cove into similar custom stock. Or, I could run the boards on the router table two or three times with a 1/2″ “half round” router bit. Possibly the 45° cuts and a kerf cove with 1/2 round grooves above and below it? Yet, that process might then need time consuming hand sanding. And, this household really likes the simple arts and crafts, mission and craftsman styles of geometric classic millwork. Simplicity is sometimes best.

So, although I am frustrated by the problem I’ve had with the Cobalt as I write today, I am happy regarding the opportunity to hypothesize regarding future success. And, I am resultantly contemplating buying a portable DeWalt table saw for expediency’s sake on this job, with about half of my next SSA benefit subsidy, and then I might either sell the Cobalt used or go through the process of discerning what parts I need and then place the order with Lowe’s or Cobalt.

Yet, in dreaming of the solution, I am perhaps slightly excessive in planning my dream shop for now. Still, I do so. Therefore, revisiting my long term objective of some day having as the cornerstone of my shop a Powermatic 5hp 230v on an RV extension cord from the Dryer 240v plug, or, on put certain machines on a new and supplemental circuit of 240v plugs that I might have an electrician install some day. Yet that’s a future plan. For now I run my home shop’s higher draw machines with by using my Sportsman Sandstorm 4000v gasoline or propane dual fuel portable generator. It’s rough.

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