Cutting an arch in 4x4 redwood

[wleingang]

Hi I just found this site and I love it. I'm wondering if you have any thoughts on cutting an archway out of a redwood 4x4.

So far I have tried cutting it multiple times on the table saw starting at one end of the arch and raising the tablesaw blade slightly each pass. It's taking forever and I'm not sure how I will clean it up so it's smooth in the end. I would use a bandsaw but I can't convince my wife that I need a tool just to cut this one thing.

Also, any good resources on hand sharpening chisels?

Thanks!

Will

[wleingang]

btw, here is what my piece looks like right now.

[PaulMarcel]

That way of nipping it away with the table saw will definitely work. You'll have a fair amount of rasping, filing, and sanding to smooth it out at the end, though.

If you have a coping or fretsaw, you could cut that by hand to get it pretty close then comes the rasping, filing, and sanding (but less of it as you won't have abrupt corners).

A jigsaw would work well, too, but don't get too close to the line since the blade will likely flex and may go beyond your line on the other side of the board.

Normally, I'd do this with a bandsaw then use an oscillating spindle sander (OSS) to very quickly smooth it out. The above ideas can take the place of the bandsaw (albeit more slowly and more cleanup). If you don't have decent rasps, files, and a flexible sanding strip, then maybe you should consider buying an OSS. Typically < $100 and you will use it a lot in the future for shaping patterns, curves, etc. Hate to say you should buy something to do it, but decent rasps and files aren't cheap either and I think you'll have more use for the OSS overall initially than the rasps and files.

[Timberwerks]

btw, here is what my piece looks like right now.

Could you make a template out of MDF and clean up the 4X4 with router & straight bit and guide bearings? I think there are long straight bits that have both top and bottom guide bearing capabilities. Other options would be belt sander, spokeshave maybe even bring the 4x4 to a shop that has a band saw. Maybe even a jig saw would help you out?

[Timberwerks]

After seeing the photo again I think a draw knife wouldl even be a good choice. Flex Cut has a very affordable very sharp draw knife with a 5" cutting edge. I would still remove as much waste as possible via the table saw or other means and use the draw knife for clean up. I think the knife is still under $30.00. If you go with the draw kinife you would need to work from booth ends of the radius. High end to middle & high end to middle, go with the grain. Then just clean up with sanding.

[wleingang]

These are all very helpful response. I will research the different methods, but I like the idea of an OSS because I can use the table to keep the sides square. I'll shoe a picture when I'm finished.

[Vic]

If you have a router, I'd go DJO's route. Make a template and router that puppy!

[Ben H]

Find a new friend with a bandsaw. If you are near Louisville, come on over.

[rob45]

OK, where did I put the Sawzall? While I'm at it, I need to down a can of Popeye's spinach to control that beast.

Seriously, all the above are good suggestions. If SWMBO says no bandsaw for this one project, then it's time for more projects. Starting with her projects first, of course!

You asked about resources for hand sharpening your chisels. Marc did a demo night covering this subject here.

[masterz]

It'll take you a long time, but you can try a coping saw. A hack saw may work a bit faster, but it may be hard to get the curve you want. Still, if you cut your kerfs first, I think it'll go fairly well.

[wleingang]

I used the router last night to cut the curve and then used a chisel on it for an hour. Today I bought a bandsaw... I will report with the results.

[wleingang]

btw, anyone in San Diego who needs access to a 12" bandsaw you can now invite yourself over to use it

[leftylen]

Now you're learning. I keep adding to my "track saw" projects list. Wife is softening.