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  1. #1
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    Notching on a 4X4?

    What is the best way to notch a 4X4 piece of wood? I am notching it for a 2X6 to make my workbench. And I don't have all the latest and greatest tools either -- miter saw, jigsaw, coping saw.

    I am sure you can tell I am fairly new to woodworking, but enjoy it very much.

  2. #2
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    RE: Notching on a 4X4?

    If those are your only power tool choices, I'd say a hand saw and chisel...might even be faster then the power tool set ups would be anyway.

    >What is the best way to notch a 4X4 piece of wood? I am
    >notching it for a 2X6 to make my workbench. And I don't
    >have all the latest and greatest tools either -- miter saw,
    >jigsaw, coping saw.
    >
    >I am sure you can tell I am fairly new to woodworking, but
    >enjoy it very much.


  3. #3
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    RE: Notching on a 4X4?

    This is how I would do it, but wait for more experienced people to respond to your post.

    1. Mark all boundaries of the notch with a square and pencil or knife. Double check your measurements after the marks are made.

    2. With a circular saw or handsaw, cut crossgrain kerfs through the area to be notched to about 1/16" less than the desired depth. Do the two edge kerfs first. Leave about 1/8" or more of wood between kerfs to keep the saw in the wood.

    3. Sharpen a 1" or wider chisel. Do a forums search on sharpening, as there are many excellent posts on this. The "scary sharp"/sandpaper method is cheapest.

    4. Use the chisel to clean and flatten the bottom of the notch.

    Andy

  4. #4
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    RE: Notching on a 4X4?

    If you have a circular saw, I agree with Andy that this would be the easiest way. Once the kerfs are cut, you should be able to knock out the pieces with a hammer and then clean up the area with a chisel.

    Bob R

  5. #5
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    RE: Notching on a 4X4?

    Couldn't knocking it out with a hammer "rip" or break off more than I want? Even if I cut a little less than my desired depth, isn't there the possibility of damage to the part I don't want to cut?

    I know it sounds silly to try to make a workbench look nice, but I am also practicing for other projects I would like to do in the future.

  6. #6
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    RE: Notching on a 4X4?

    The wood should break at the weakest point, which would be in the portion with the saw kerfs. Try it on a piece of scrap if you're concerned about using this method.

    Bob R

  7. #7
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    RE: Notching on a 4X4?

    ok, will do. thanks a lot.

  8. #8
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    RE: Notching on a 4X4?

    Eric,
    Go with the saw kerfs and then use a chisel. Go slow, easy and work your way in. You shouldn't have any trouble even with a dull chisel.

    If you make just a couple of cuts, one on each side of the dado then use your coping saw. Then if necessary, use the chisel to smooth out the bottom of the dado.

  9. #9
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    RE: Notching on a 4X4?

    Eric, lacking a handheld circular saw, I'd cut the ends of the dado with a handsaw. Then I'd attack the sides & face of that waste with a chisel, working my way toward the bottom of the dado. At the bottom, I'd get extra-sure my chisel was as deadly sharp as it could be & skim the bottom with it to flatten it out - working WITH the grain, not against it.

    Rich, your new sig line's gonna kill me from gigglin'! :)

    -- Tim --

    If today
    I have not helped bring a smile
    To at least one face,
    Then today
    Was a wasted day.

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