How to Make Very Thin Flat 4x4 Boards with Limited Tools
I have many relatively thin pieces of scrap exotic woods. Most are just over 4 inches wide by 8 to 12 inches long. Some are not very thick to begin with, but most are around 1/4 to 1/2 inch thick. Many have various defects with tapered thicknesses, twists, cups, etc.
What I would like to do is turn them into very thin 4x4 inch boards. By "very thin", I mean 1/16 inch thick. (I also need 1/8 inch, but if I can make quality 1/16 boards, then 1/8 inch boards should be easy.) I plan to laminate them into three-layer "plywood". I plan to glue a 1/16, a 1/8, and a 1/16 board together to make 1/4 inch thick, 4x4 inch squares. It sounds simple enough, huh?
-> How would you make flat, smooth, perfect 4x4 inch boards that are a nice, even 1/16th inch thick?
Here are some of tools at my disposal:
* DW735 Planer
* 14 inch Bandsaw
* Table saw
* Random orbital sander
* Underpowered crappy drill press with a 3/8 inch chuck
* Ancient handheld belt sander. It is metal and heavy and challenging to use
* Various hand tools, including hand planes (in rough shape), chisels, sanding blocks, etc.
* Harbor Freight Workbench - one vise, non-standard dog holes, with dogs too high for 1/16 boards
* Decent double-stick tape
Here are tools that I do NOT have:
* No power jointer
* No stationary belt, disk, or oscillating spindle sander.
Here is my current thinking, but I would appreciate your advice:
* Some kind of sled on the planer? (Can it make nice 1/16 boards without damaging them or sucking them in?)
* Rough resaw on the bandsaw, then hand sanding to get out the cut marks? Can I make them a true, flat 1/16 inch? That might be challenging.
* Anchor them somehow and try to hand plane them? It would take a lot of restoration work to get the hand planes ready, plus learning good hand plane technique.
* Borrow a friend's power jointer and use it some way?
* Some combination of the above?
Note: I do not mind buying tools. If there is a tool that I need for this job, say it.
Last edited by Tool Agnostic; 06-15-2018 at 10:53 AM.