>Various cauls available for sale, but I was considering making these using >either router or table saw and some appropriate machinable >plastic. Wondered if anyone had any tips (besides the obvious - "buy them"). > >-Mark I've made a few sets out of aluminum, polypropylene, or maple. The first few sets were because the commercial versions weren't available yet, and the others were because of odd sizing, or timing - when I needed them right now and had neglected to order them. Making them is interesting, but buying them is easier. The router works best for gang-milling the tongue, but you'd better have an accurately thicknessed stock to work with. Then separate individual cauls with table saw or band saw. Eye protection REQUIRED, as well as ear protection. Watch your fingers, and stop and count periodically. Jig up and use something not a part of yourself as a push stick. Bad things happen very quickly and with considerable violence with small parts in whirling blades. A maple body with the appropriate thickness aluminum tongue inlay works well too, and makes getting a uniform thickness tongue a lot easier. If you use all maple, saturate them in CA or epoxy after milling to glue-proof them for later ease of cleanup. Then just buy your next set. It's cheaper and safer. Ron N
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