Being able to make a crown molding all by oneself is every woodworker’s dream. With a table saw, you can make a classic crown molding. To make it, you need other materials such as PVC pipe, scraper, elbow grease, a block plane, and sandpaper.
Making Crown Molding – The process
To create the molding, you need to draw a profile on both ends of a blank and then cut away the parts you don’t need by using the profile that you drew to fix the blade and fence height for each cut.
The cuts might not score a profile line, so besides, you need to scrape, plan, and sand to finish the job. Next, create some curved shapes by moving the blank on the blade at a certain angle or changing its height. You can also make flat surfaces by tilting the blade.
For this, you have to make a full-sized pattern of your molding by decreasing it to 78% via a photocopier. Use this pattern to outline the molding’s profile on both the ends of the molding blanks.
Keep in mind that the blanks have to be of the same thickness and width, though the lengths might vary.
Begin by slicing the coves that are matched to the concave curves. For this cut, you need a clamped fence at an angle and few passes while raising the blade 1/16 inches each time.
Cut the molding coves at the bottom by setting the blade at ¼ inch and setting the fence 18 degrees.
Cut and clean the fillet
You can cut the fillet with a rip fence. It needs to be angled at 52 degrees so that the blade doesn’t tilt too much while cutting directly in line with the face. Angle the blade at 90 degrees so that the teeth meet the face.
Next, you have to clean the fillet using a card scraper with a V shaped groove. The card scrapers are cheap and easy to use.
Install a tall fence
You must install a fence to slice the spring angle bevel at the back of the molding. This angle is formed between the crown molding and the cabinet; 45 degrees and 38 degrees are two standard angles.
Cut the top fillet
Next, you need to cut the top fillet of the molding at the same angle to be equal to the spring angle bevel. This will make the fillet vertical when you install the molding. Flip the molding and adjust the fence.
Slice the top edge
With the molding flat, cut the top edge on the saw. Rotate the molding at a 90-degree angle from the previous step so that you can cut a square corner without having to change the angle of the blade.
Cut the square bottom edge
To do this, you have to move the fence to the other side of the blade. Leave it at the same angle and also keep the exact position of the molding.
Lastly, remove the ridge support and, with a block plane, shape the top part of the convex curve. Also, plane down the flare on the bottom part of the cove.
And that is all there is to it when it comes to making crown molding.