Bought some wood today to make new stands for the rails for my art photography. I have a conundrum. I had 6 lengths cut, 95mm wide by 1147mm long, from 18mm deep MDF. These 6 pieces had to be cut from two pieces of MDF, so the 1147 length was about 1mm out for two of the lengths (numbers 2 and 5 in the picture; I chose these as the central plank). Each width isn't perfect but this is less important. The length needs to be as accurate as possible. I've glued them together to make 2 bunches of 3. Here is the end:
This, ideally, should be completely flat. I need to work out the best way to do this. If I had a band saw or table circular saw (or table anything) this would be easy, or much easier, but I haven't. I could use a router, but 72x95mm is a big edge, I have no router bits 72 or 95mm long (the depth in the view above is 95mm). I wondered about fitting a cutting drill to the router. I could sand it flat, but would ideally need a right-angle sanding table. My drum sander is best at removing wood but is hand-held, like all of my sanders. Alternatively, I could saw it by hand somehow. The jigsaw should be deep enough. A hand cut would probably be more accurate than the current edge, but not perfect, and it might be less accurate. The 1mm tolerance there now might be enough.
Alternatively I could cut it shorter and glue a flat piece accurately on top, using a gap filling plaster-type glue. I'd need to experiment again with glues. I've had some good results from wood glue and chalk to make a thick glue; but I'd have to do this separately for each of the two stands (the two groups of three) so that itself might make the results less accurate than they are now; it's most important that they are the same, the exact height isn't so important.




