Table Saw: Legs

Step 1. Cut legs to rough length

• Using a table saw

  • Cut the 2x4s so there are 4 pieces 41 inches long

  • Cut 2 pieces of 2x4 so they are 17 inches long

Step 2. Remove round over on both sides

• I want the legs to be flat. 2x4s have a slightly rounded edge

• Using a table saw

  • Trim off ~1/8 inch on both sides of the 2x4s

Step 3. Drill pilot holes

• Each leg consists of two pieces of 2x4 glued together

• Mark the legs using something like: Support, [Front Inside, Front Outside] and [Back Inside and Back Outside]

• On the Inside 40 inch 2x4s measure and mark 8", 16", 24" and 32"

• Drill pilot holes at the marks

Step 4. Drill pilot holes

• Each leg consists of two pieces of 2x4 glued together

• Mark the legs using something like: Support, [Front Inside, Front Outside] and [Back Inside and Back Outside]

• On the Inside 40 inch 2x4s measure and mark 8", 16", 24" and 32"

• On one Support measure and mark 5" and 11"

• Drill pilot holes with counter sink bit at the marks

Step 5. Glue legs together

• On the legs without pilot holes, spread glue

• Lay the legs with the pilot holes on the corresponding leg with glue

• Align the edges

• Insert screws in the pilot holes and tighten - don't over tighten

• The screw head should be flush with surface of the wood

• Add clamps as required

• With a damp rag or paper tool wipe off any glue that oozes out

• I put the legs on some wood scraps to dry so they aren't laying on the floor

• Wait until the next day for the glue to dry

Step 6. Cut legs to final length

• Using a table saw

  • Cut ~1/2" from each end of the 2x4s

    • The front and back legs should be 41" long

    • The support leg should be 16" long