SuperStation Project - Standing Bar  - "Cutting the Panels"

	In looking for another SuperStation project, my friend, Sal, said that a bar was on his wife's to do list, so I said "let's make one."    It didn't take me long to see that Rockler Hardware had plans for a very nice looking bar. Normally, I would draw plans from scratch, but this time I thought it would be interesting to see how it would be to work from a set of finished plans. After all, they only cost $20.00 or so — I should be able to make that up in time saved from having a complete set of plans, not to mention errors I might make from doing my own.
When I received the plans, I looked them over very carefully. Clearly they were professionally done, and the various charts and diagrams should make the building of the 2' X 6' bar much easier.    But one thing I missed right off the bat was any detailing of total panels and board feet of solid stock needed. And, to me, that is a real short coming. There are 90 pieces to cut. Each piece is exactly described...but you (or I) have to put each piece on a cut list and add it all up to order the right material. That was disappointing, but I got over it.
	I started doing this wood breakout by doing what I usually do, sitting down and marking on a piece of yellow paper each and every part. For 90 pieces it took two hours and a lot of adding of numbers — an area where errors can creep in. [23 1/8 by 6 1/4 plus 17 1/2 by 8, etc...]
So I turned to my computer and the art program I use, Corel Draw. I started by laying out a page that was 48" by 96", the size of hardwood ply, of course. Then I took one part at a time and used the Plan's dimensions to create a block and then moved the block onto the page. I didn't have to add the pieces up as long as I didn't overlap the blocks.    I found that I would need 3 sheets of 3/4 ply...I had 3 pages of little blocks.    I carefully specified in each block, the part number, description, and dimensions.
	Printed out, these pages gave me a cutting plan for the panels. The draw program took about an hour to complete with a lot of that time spent double checking the numbers.    So here I am at the first panel and ready to start cutting.
I said that this was a project for the SuperStation — and it is. But very often, I find it is easier to make the first  panel cuts with the panels resting on horses and using my trusty circular saw. I don't usually have an assistant to help me heft the whole panels onto the table saw, and I am limited in the maximum size my sliding table can handle — not a whole 4' X 8' panel.    Here, I am setting the depth of cut to just exceed the thickness of the 3/4" panel. You will note that I have the ply laying on top a 1" board of foam insulation material. This is a great way to keep the board raised above the horses. I cut slightly into the foam material but not the horses. The foam panels are used over and over and when they are really shot, they are discarded.
	I clamp a straight edge onto my board where I want to make my first rip. I set it at the width I want plus 1 1/8", the distance from the edge of the saw to the blade.    There are some good straight edges that can handle the 96" length but I bought an 8' level that could serve double duty. I would stay away from the 8' straight edges that are two lengths clamped together in the middle. The one I had was never really straight...kind of defeated the idea of a straight edge. This works very well.
I try to keep my left hand on the straight edge as I proceed with the cut. If, for any reason, the straight edge doesn't lay flat to the panel, the saw can move under the straight edge and make a mess of the cut. This can happen where the panel isn't supported well and sags.     By the way, I find this 6" saw perfect for these panel cuts. It is easier to handle than my 7 1/4" unit. With a 40T carbide blade on it, it makes a great cut.
	As I make each rip, I add a piece of blue masking tape and mark the part number from the Rockler Plan list and the dimensions. I will make the final cuts at the SuperStation.    Let me discuss the issue of cutting twice. My portable saw makes a very good finished cut, but it isn't as good as the table saw. I usually cut these parts leaving about 1/4" so that I can make the final trim later. In addition, I add more waste to be cut off if the panel's edges are less than perfect.
At the SuperStation, I make the cross cuts.
	And then make the final rip using the Incra TS III fence. While this may seem like an extra step at times, I feel that I can get the most precise dimensions of each and every part when I do it this way — unless, of course, I simply make an error in writing the dimension. I check and double check to reduce that possibility. After all, good hardwood stock is expensive.    Since there are so many parts (90), I cut one panel at a time. At this point, I have 11 parts dimensioned. 79 to go. So on to the rest of the plywood cuts.