Need advice on board flattening
I build table and wine racks that the legs on average, are around 12"x3" crossection but are curved and tapered and join the tabletop at an angle. Joining isn't the problem as much as reproducing a consistently horizontal cutoff. I have built a sled that can be adjusted to a majority of heights and cuts at dead on horizontal but here's the problem: my work involves step laminating so there are a couple of hidden trim nails through each piece. The ideal situation would be using a router but I cannot find a square router bit that could handle a bit of steel without completely destroying itself. The other choice is to set up a horizontal cutoff saw with a wood/metal blade: the only problem being, I am limited to about 2" worth of cut. That would give a nice tight exterior cut and leave the sanding to the hidden center (see pic#1).
The other odd cutting problem I have is making extremely long, shallow cuts (like a shallow slice off a potato) - I also have designed curved sections 16"x40" (see pic#2) that sit up off the wall but are flush on the back side. This one would be really ideal for a leveling router but again, the nails. Right now I am sanding and checking etc. but am not happy with the amount of time it is taking. A super flat/hard/rough sanding disc may work but making passes would likely take as long and sanding and checking for flush etc.
Get your brains together boys, it may be a rough ride. And thanks for all the help in advance!