Still has all 9 fingers
Join Date: Apr 2019
Location: Indianapolis, IN
How to cut these post details?
I'm new here but not new to woodworking. I usually work with sheet goods and stuff under 8/4. Our mailbox post is rotting and I'm not about to pay $250.00 for what literally amounts to a 10' pressure treated 6x6 with 2 dado cuts and some detail that I can make and set in a weekend. Our HOA demands a particular style as I'm sure most do. The detail at the top of the post is similar to the attached picture (almost identical, just a tighter radius at the top).
The semicircle notch on ours is 2", which I'm guessing is done by router with a round nose bit. One could also clamp the to another piece of stock and use a deep hole cutter and put the bit right on seam. Either way, easy peasy lemon squeezy...
The rounded bevel/chamfer at the cap is what has me baffled. I'm guessing a bandsaw was involved, but this is going to be heavy 6' post. I know that there are longer reciprocating/jigsaw blades, but I'm guessing they flex and drift too much to make this kind of cut.
I could also remove as much scrap as possible and sand it on the disc/drum/belt sander, but that seems like a massive waste of time.
I'm sure that the actual answer is simple, which is why I'm not seeing it. Suggestions anyone?