Best way to make small parts flat and square????

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Forum topic by Pete21 posted 05-20-2017 04:30 PM 788 views 0 times favorited 7 replies Add to Favorites Watch
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3 posts in 1212 days

05-20-2017 04:30 PM

Topic tags/keywords: question

I’m making a jewelry box which requires small (.150”Thick X .500” Wide X 2.0”Long) corner splines. I’ve tried hand sanding and using a belt sander but create a lot of variations in thickness and can’t get a good fit in the joint. Also tried sanding a larger piece flat and cutting it to size but get the same variation in sanding. Any ideas on how to get a flat consistent surface on something this small.

7 replies so far

View TheFridge's profile


10859 posts in 2260 days

#1 posted 05-20-2017 05:02 PM

Cut a block 1/2×2x whatever with the proper grain orientation to slice off .15 pieces.

Use a tablesaw sled. Set a stop block for .150 cuts. Use a wide push block to hold the block and the soon to be cut piece down to the sled and go to town.

or plane some stock down to 1/2 and rip some long .15 pieces against the fence. Use push block to finish the cut.

-- Shooting down the walls of heartache. Bang bang. I am. The warrior.

View Rich's profile (online now)


5619 posts in 1364 days

#2 posted 05-20-2017 05:58 PM

+1 on Fridge’s comment. Plane it to 0.150” and rip 1/2” strips, or plane it to 1/2” and rip 0.150” strips. Either way will get you there.

-- Half of what we read or hear about finishing is right. We just don’t know which half! — Bob Flexner

View William Shelley's profile

William Shelley

609 posts in 2244 days

#3 posted 05-20-2017 06:00 PM

+1 on Fridge s comment. Plane it to 0.150” and rip 1/2” strips, or plane it to 1/2” and rip 0.150” strips. Either way will get you there.

- RichTaylor

Personally, I’d plane to 0.150 and rip the 1/2” strips since for a spline the thickness will need to be spot-on but the width might not need to be as precise, unless the end of the spline is visible I guess.

-- Woodworking from an engineer's perspective

View Loren's profile


10477 posts in 4422 days

#4 posted 05-20-2017 06:30 PM

I’ve done it a few different ways depending
on what machinery I had available. One
can try cutting “fingers” on the end of a
block on the table saw, using a tenoning
jig type fixture to hold the work upright,
then cutting the fingers off. Still, setting
the cut up properly is fussy business.

Another way to do it which I think I like
better is to use a band saw with a fence
and cut the stock a little thick. Then
stick it to a flat surface using double-sided
carpet tape and work it down to thickness
with a hand plane. It’s also possible to
skip the tape and put a very low stop at
the end of the work bench. The stock will
have a tendency to skip over the stop and
take flight but without being stuck down
it is easier to be sure of the right thickness.

Still another way to do it, which I have not
tried, is a tool called a Saf-T-Planer chucked
in a drill press.

Another way is to mount a sanding drum on
a drill press and using a fence with a spring
on it pull the pieces in between the fence
and the drum.

View 000's profile


2859 posts in 1674 days

#5 posted 05-21-2017 02:15 AM

I would use a long board (26” or so) of 1/2” material and set the saw for the thickness (.150)
Run the board through the saw about 10” or so and lift it out. (SHUT SAW OFF FIRST) Depending on how many pieces you need you could turn the board over and do the same to the opposite edge and/or turn the board around and do those two edges also.
Then cut them to 2” on the chop saw.

“ONLY” do it this way if you are comfortable!!

View MrUnix's profile


8094 posts in 2973 days

#6 posted 05-21-2017 02:28 AM

Google “Thin Rip Jig” And make strips whatever thickness you need for miles. Plenty of store bought contraptions out there, or pretty easy to make your own out of scrap. Some local examples can be seen here and here just to name a few. Here is my version, used on both table and band saw:


-- Brad in FL - In Dog I trust... everything else is questionable

View Dan P's profile

Dan P

750 posts in 2666 days

#7 posted 05-21-2017 01:39 PM

the way this guy does it looks like it should work pretty well.

-- Daniel P

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