Cutting Lap Joints in the X-Brace

[Darryl Young]

I will soon be cutting the lap joint in the X-brace and I'm trying to decide the most accurate and easy method to do this.......so I'm curious how you guys do it. Do you mind sharing?

I could easily use my table saw........but not exactly sure how to get the angle to match exactly. Easy to get close but I want the angle perfect. My X brace angle is 95 deg so I think I would have to angle my miter gauge 2.5 deg on way then 2.5 deg the other way to cut the slot in both chanels and I'm not sure how to angle the same amount both directions.

I've marked the lines on the X-brace and I can just cut the sides slightly narrow with a dovetail saw (Japanese pull saw) then sand to fit the exact width. Only issue here is getting the right depth and leaving the bottom of the channel smooth. I can sand the sides but it wold be difficult to sand the bottom of the channel (need to use something thinner than the brace).

I can get pretty close just using the dovetail saw, sanding the sides of the channel to the correct width if I have a way to adjust the depth of the channel.

Look forward to hearing your methods.

[tippie53]

I use my table saw. This isn't that hard , set the miter to 98 degree. I radius them and set them in a pair and nipple the joint. You want this joint tight as you will be sanding the braces. Make some sample cuts and you will dial in the process pretty fast.

[Darryl Young]

I'm thinking about clamping the X-brace leg in a small vice lining up the depth of the cut with the top of the vice so it's impossible to cut too far. Then maybe I can use a sharp chisel to gradually increase the depth of cut till the braces overlap the correct amount. Sound doable?

[Darryl Young]

John, you posted while I was typing my second post.

Can I make one angle adjustment on the miter saw and cut both slots at once? I couldn't figure out a way to do this. The X-brace angle is what is used on the Norman Blake and it appears to be 95deg. I was thinking I needed to angle the miter gauge one way 2.5deg and cut one brace, then angle the miter gauge the other direction 2.5deg to cut the other brace. Am I wrong? Hopefully I am as it would be much easier if I didn't need to adjust twice.

[Jim_H]

I do it the hard way. I just line the braces up over the plan and transfer a line, then cut it with a razor saw slightly inside the lines. chisels and small flat hardwood sanding blocks creep up on the fit until it's just right.

[CET]

I do it by hand as well. I made something similar to the fixture shown here http://www.kennethmichaelguitars.com/Xb ... guide.html
It was easy to make and works great.

you may post a picture of yours

Edit: I assumed it was OK to post the link because the maker of the jig and owner of the website does not sell the jig...it is in the "Tips and Techniques" section.

[Darryl Young]

Wow, we are going to remove any link that may provide ideas because it may be commercial? Doesn't this severly limit the usefulness of the forum? So can we even show a pic of an idea if someone somewhere sells it? How about showing a link to a StewMac tool or a tool from LMI?

Aren't we cutting our own throats here?

[Kevin Sjostrand]

That seemed a bit steep to take the link out, but then we don't know that it might have been an endorsement.
I hope we aren't going overboard on what can be included.

Kevin

[tippie53]

I contacted the mods to let them know I did it and I promise to keep my fingers off all buttons in the future. Redo the link and allow the mods to decide.

[CET]

Post the link yourself, John. I already did it once. I'm out.