cutting timberframe knee brace details

[canadamike]

Hi,

I am running a large project where we need to install about 25 timberframe knee braces, all are decorative. Final depth of the braces will be 5 inches or 127 mm. There is a detail at both ends of the brace, and due to size and weight I am thinking we will not get an accurate cut using a bandsaw (we have an 18" bandsaw and small blade etc), and we do not have enough space to set up a large table to stabilize the pieces.

So my questions to all the experience out there...will one of the Festool jig saws do this accurately?

We do not want to fork out the $ for a portable bandsaw mill.

Or we could get it CNC'd. Just would like to do this ourselves.

Looking forward to all the input!
[attachimg=1]

 

[Jason Kehl]

I tried to do something similar with the Trion and the cut was no where near acceptable. There is simply too much blade wander, following the line at the top is one thing but the blade will be way off on the other end. The cut quality of the Carvex is no better than the Trion. I would try a test cut on your 18" bandsaw and see how it works out before pursuing other options.

j

 

[ear3]

I've gotten plumb cuts with the Carvex on a 4x4, but that was a straight cut.  A plumb 5" curve cut is probably pushing the limits of the Carvex past what it can do.

You could always ask [member=3891]WarnerConstCo.[/member] for tips -- he posted a video once of this wicked beast of a scroll saw with which he made some similar pieces, though with even more elaborate interior cutouts. 

 

[greg mann]

I would not expect ANY jigsaw to outperform a bandsaw on the type of cuts you are describing. With the number of pieces you referred to I would take the time to find a good way to use the bandsaw.

 

[Holmz]

The p1cc can do it, but it uses the same Bosch blade that one would be using in the Carvex or Trion. So if the blade cannot do it then you are hosered.
I got a fantastic result in some super dry 4" pine. Then in another piece 75-mm thick doing more of a rip cut the blade was getting massive flex.

You will either be lucky or you will need a bandsaw.

Maybe there is a place nearby to do it for you? or where you can hire the tool?

 

[WarnerConstCo.]

Those are simple to cut on a BS. Maybe your 18" BS sucks, I don't know.

I cut these with my 36" BS. The top of the Ipe 6x6 was only difficult due to its weight and length.

 

[canadamike]

Thanks for the comments!

We'll build a BS table extension tomorrow and see how it goes. We are struggling with the lack of space to keep the stock flat so we get a good cut. Really want to do this, but we may not have enough space. Miss my old shop!

I'll let you know how it turns out.