How would you make a jig to facilitate making this star?

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  • BadeMillsap
    Senior Member
    • Dec 2005
    • 868
    • Bulverde, Texas, USA.
    • Grizzly G1023SL

    #1

    How would you make a jig to facilitate making this star?

    I have a bee in my bonnet to make several small and larger projects that would all in one fashion or another feature a "raised Texas Star" like the one pictured below (this one being metal but it shows what I am looking for).

    So ... my problem is ... since each star will have 10 pieces (5 identical pairs) I need to fashion a jig that will allow me to make these both accurately and with as little fuss as possible. Ideally I want the actual "size" of the star to be variable but making a separate jig(s) to make each size is not a problem. The problem is ... how do I construct a jig to cut the appropriate angles on my table saw? I see these things basically everywhere (in Texas) so it can't be actual rocket science but is apparently beyond my ken .... I'd appreciate any suggestions and a "drawing" or picture is worth about 20 thousand words in my case.
    Attached Files
    "Like an old desperado, I paint the town beige ..." REK
    Bade Millsap
    Bulverde, Texas
    => Bade's Personal Web Log
    => Bade's Lutherie Web Log
  • cabinetman
    Gone but not Forgotten RIP
    • Jun 2006
    • 15216
    • So. Florida
    • Delta

    #2
    The math and geometry can get confusing. Here's a relief method for making one in paper, for a model. You might make one and use the dimensions for what you would need in wood.

    It might be easier to configure jigs for a solid wood piece than if done with sheet goods. A sample could be done with a pine glue up.
    .

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    • Daryl
      Senior Member
      • May 2004
      • 831
      • .

      #3
      Probably pretty simple if you are sharp with compound miters. By the way, I have seen these at craft stores made from wood.
      Sometimes the old man passed out and left the am radio on so I got to hear the oldie songs and current event kind of things

      Comment

      • fcpjax
        Forum Newbie
        • Sep 2005
        • 28
        • Jacksonville, Florida USA.
        • Frankensaw - dual Ryobi BT3000s

        #4
        Hi Bade,
        I did this several years ago when my wife got on her stars for the mantle kick....
        After trying freehand for several weeks, real men don't use jigs...
        I discovered this project is impossible without a jig...Ha
        Hey, some people have to learn the hard way.....
        Anyway, here is a site that has my attempted to explain my jigs.
        Hope it helps.
        http://www.woodworkstuff.net/Star5.html
        Bob Pepple
        Jacksonville, FL

        Comment

        • BadeMillsap
          Senior Member
          • Dec 2005
          • 868
          • Bulverde, Texas, USA.
          • Grizzly G1023SL

          #5
          Thank you guys!

          Hey guys ... thank you for the replies .... I think if I can study his jigs long enough Bob (fcpjax) has accomplished what I need to do I just have to digest his excellent write up ...
          "Like an old desperado, I paint the town beige ..." REK
          Bade Millsap
          Bulverde, Texas
          => Bade's Personal Web Log
          => Bade's Lutherie Web Log

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