End to Face Joint
At some point I'm going to making some speaker stands out of red oak. The stands will have bases and tops composed of a single 1x8 board each, with 4 1x3's making the supports for the tops, one going parallel with each side - looking straight down at them they're arranged like a square shape that's been opened up by cutting the corners off.
Structurally is this design suitable for holding up to 10lbs? I assume with oak it would be perfectly stable. Were only talking 4 feet tall at the most.
My issue here is... how do I join the ends of the 1x3's to the faces of the 1x8's? End grain isn't going to glue well to a face. And screws alone are going to be too weak going into those ends, not to mention prone to splitting. I know this much.
I don't have a lot of tools to work with here. I have no table saw or router. If there's a tool I can get to pull this off that I will use lots, I'll strongly consider. As far as tools go for making joints... I seem to have neglected buying any. Don't even have a kreg jig :/
I was thinking dowels would be the way to go. I'll buy a doweling jig to accommodate that, as I can see myself using it frequently. But how feasible is it to precisely tap a wide board closer to the middle with one of those? Is it something I can pull off with just a power drill or do I need a press? What about those hand crank ones? How hard are they really to line up by simply measuring, marking, and drilling with brad points? Or maybe I could make a jig to better accomplish this with what I have?
The only other thing I can think of isn't elegant and I might scrap a board or two doing it, but I could cut out holes in the bases and tops for the supports to slip right through. I could use a jigsaw and a drum sander drill bit to accomplish that. Getting it all clean and snug might be tough, though. Not to mention overly tedious for what I'm doing.
I was planning to make them "floating" with 1x2's centered on the edges for trim around them and feeties hidden underneath anyway, so there will be room for the boards to poke through on the bottoms. I could then attach small pieces of wood to the undersides right adjacent to the 1x3's poking though and then attach those to the 1x3's. Screws and glue. This would be sturdy I'm sure. And it can all be hidden easily. Just not the most practical route.
Any ideas here? I'm open to just about anything that makes them look like they're butted flush against the faces. I'm gonna stain and lacquer so it needs to look good. Maybe there's an adhesive I can use that might work? What even is the proper way to butt end grain to the center of a face?
Life's too short to be caught using cheap sandpaper.