I dont see anything on frames yet, so will post how I make mine..
I use foundation-less, but the same principle applies... More on that later...
One 12' 2 x 8 x 12 makes 49 top, and bottom bars.. Excluding knots and splits of course..
At the time of taking these pics I was using 1 x 1 top bars and 5/8 bottom bars.. I have since changes slightly to 7/8 top bars so i dont have to "shave" the shoulders...
The bar to the right is simply a 19 inch piece cut from the 2x material 7/8" wide.
Next is the same piece trimmed to 7/8 x 7/8 the piece trimmed off will become the bottom bar.
The next piece is showing how I trimmed the shoulders which I dont do now
The last two bars are after shaving the ends and cutting the bevel as well as trimming the bottom bar to 3/8 x 5/8 and 17 3/4 long. To shave the ends down, some folks use a router, I just use the table saw setting the guide to one inch from the outside of the blade, then lower the blade so it "leaves" 3/8 of an inch. Keep your fingers back, and gently SHAVE the wood away. I use a 60 tooth Diablo blade so it leaves a smooth finish. slide the bar in easy JUST touching the blade until it comes up against the guide. Then work it back and forth until your end is shaved.. flip the bar around and do the other side.. GREAT now 48 left to go!!! :mrgreen:
I do a pile of them all at once, set my stool beside the saw and go to work...
when the ends are shaved reset your table saw to 45 degrees and put the guide on the other side of the blade. Adjust it in, and the blade up so that you JUST miss the shaved section and the blade protrudes from the top very slightly, and run the bar through.
Flip it around and run it through again.. You should have a perfectly centered point on the bar now... and that bar is finished.
These bars were all cut from garbage 2x material I got for free;
Your looking at about 40 top and bottom bars cut from scrap that cost me nothing.. Occasionlay, even in wood you buy you hit Knots and splits as the broken bar on the right shows... Its just part of the process.. deal with it and keep on rolling!
the frames done this way should fit together snugly.. this is a frame put together, no nails, no glue.. it fits snugly together AS IS, and this is the goal when your making them;
For the side bars....
cut a piece of 2 x 8, 2 x 10, 2 x 12... You CAN use 2 x 4's if thats all you have but the wider material makes more end plates for less work... ANyhow, cut the 2x material to length.. I use mediums exclusively. this will work for shallows, but cutting the kerf for deeps you will need another method..
I plane the blocks of 2x material to 1 3/8 inch in my Dewalt planer. I try to do several of these at a time as well..
I raise my table saw blade all the way up, and set the guide to shave the side of the block standing on end. I take 1/8 of an inch off each side of the block usually in about two or three passes on each side, until the bottom measures 1 1/8 inch. Its easier and quicker than it sounds.
I set my router table up with a 5/8 bit, and center the bit for the narrower side of the block and run it through. Try to make sure it is centered as best possible, because this setting will also determine the width of your top notches..
Once the bottom is done, flip the block and run the top through. Turn it around, and run the other side through.. if done right the top notch should be 7/8, and your top bars will fit snugly without splitting the side plates..
Now I reset my table saw to about 3/8" or JUST slightly over and adjust the blade up to just clear the top of the block, and begin running the 2x through using a push stick..
The last two cuts can be tricky, USE CARE or throw away the last piece. Always make sure your blade is SHARP.. more on that later too..
I put a bucket at the back of the saw and just use the push stick to run the pieces off the back of the table into the bucket.
I built a jig to assemble my frames.. will get a pic of it soon... now all thats left is TO assemble them. Glue the notches in the side plates, press the bottom bars in and nail..
Continued below... can ONLY post ten URL's :(
