Originally Posted by BFauska
Outside corners are not a problem for getting sharp edges with a routing jig. All of the corners in your shape would be outside corners. You may have a hard time holding the fig in place, a nice strong double-sided tape might work.
Good Luck and have fun,
You might be right. The "hold your mouth just right" cut is where the diag. line intersects the square in the middle. I need to end that cut at exactly the right spot so not to take off any material on the inside edge of the square. Doable but not something you want to attempt after a few beers
Originally Posted by bpape
Why not save yourself a lot of hassle and route the 'X' and then the WHOLE square. Then add the square back in later.
I thought about just doing the "X" then reattaching the square. The issue is having the maple grain match up with the surrounding grain. One idea (if I went your direction) if to buy something exotic for the center (stained dark brown like the walls). A few woods I've always loved are Bubinga, Burlwood and Birds-eye Maple. When I was over at Woodcraft the other day, they had a bag of a dozen or so of various veneers (some rather exotic) for I think $20 (8" x 14"). This might be a low cost way to get the wood I want without having to purchase an entire 4x8 sheet.
Burlwood (lots of character in this wood)
Veneer Pack at Woodcrafters
However, one flaw in my plan -- will it be okay if these are the only (2) places in the room with this type of wood? I did not plan to have the "X" accent in any of the side or rear columns because that area will be covered up with grill cloth. I am planning to build a shallow but wide bar table behind the HT seating -- could use that wood there (but that might get rather expensive for such a unimportant fixture (looks wise) in the room). Heaven forbid a wet glass left a permanent ring in the wood because a guest forgot their coaster
Originally Posted by hinadog
I agree with the jig concept. Build yourself a template out of plywood that does the X and the square at the same time, clamp it to the piece and use a plunge router and be done with it. You'd have consistent cuts for all the columns. Doing individual cuts leads to human error, you want to eliminate that.
Bud, yes an all-in-one jig may be the way to go. I need to come up with a jig design. However I am with you on the human error factor here and would love to minimize that as much as possible. I can't seem to think up a single piece design that could handle the inner square and angled sides. I'm almost thinking it will need to be a 2-piece design -- just can't think of it yet. Ideas?