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How to Make Back Bracing

Ok Jigs are easy to make and while this is based on a table saw they can be modified.

I start with bracing stock and I make 1 sizes. 5/16 and 1/4. here is the feather board set up I use to rip the stock and set the angle of the side of the brace.

Once this process is done I like to radius the stock pieces. I use a flex jig here. I have this set for 28 foot. There is a stop, this will be the upper part of the brace, the center stop is at the thickest part of the brace right at the X juncture.

Now I have a rough shaped and radiused brace blank. There is a key to making a perfect notch. What I do is measure the saw kerf and subtract that from the thickness of the stock material. In this case I have a .305 brace and a kerf of .100 This is .205. I will make my stop block .200. This will allow me a bit to sand off for that perfect fit.

Now I have a rough shaped and radiused brace blank. There is a key to making a perfect notch. What I do is measure the saw kerf and subtract that from the thickness of the stock material. In this case I have a .305 brace and a kerf of .100 This is .205. I will make my stop block .200. This will allow me a bit to sand off for that perfect fit. Note the stop block against the rip fence. I back my brace against the block run through the saw set up and remove the block and run the stock again. This leaves a nib that needs to be cleared. Then I check my fit. You can adjust the angle with the miter attachment. Be sure to use a back block on the miter gauge for best results.

The final step is end taper. I use this set up for tapering the X braces. I then sand the braces and do the final bracing shaping on the top. I make all the braces starting with longest then thickest and continue from the larger braces to the smallest.

All done, a pile of pieces with all the bracing ready for tops. There are 75 sets of bracing made in less than 8 hrs. While it may take time to make jigs, the production and repeatability of the process can make them very useful. If you liked this, please Facebook Like and Google Plus One at the bottom.

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Bending forms, side benders, jigs, sanders