The Milling Process (S4S)
The Jointer
The jointer creates a dead-flat reference face and a dead-square reference edge. These two surfaces are the foundation for all subsequent machine cuts. If you skip or rush jointing, every measurement that follows carries accumulated error. Set the infeed table 0.5–1mm below the outfeed. Pass at a consistent feed rate. Always joint with the grain, not against it.
The Thickness Planer
The planer makes the second face parallel to the first jointed face and brings the board to exact final thickness. Always feed the jointed face down — the machine references from that face. Take passes of 0.5–1mm maximum. Snipe (a slightly deeper cut at the start and end of the board) is common — leave 50mm extra length and trim it off after milling.
The Table Saw
The table saw rips to final width and crosscuts to final length. Always use the rip fence for ripping — never freehand. Always use a crosscut sled or mitre fence for crosscutting — never use the rip fence as a length stop for crosscuts (kickback risk). The blade should protrude only 6mm above the workpiece.
Table Saw Mastery
Blades and Kerf
Rip blades: 24 teeth, flat-top grind, wide gullets — removes large chips along the grain quickly. Crosscut blades: 60–80 teeth, alternate-top bevel — clean, splinter-free cuts across the grain. Combination blades: 40 teeth — a workable compromise. Kerf is the width of material removed — typically 3mm standard, 1.5mm thin-kerf. Thin-kerf blades are useful on smaller motors or for veneer work.
Crosscut Sleds & Jigs
A crosscut sled rides in the table saw's mitre slots and makes perfectly square, repeatable 90° cuts far more safely and accurately than the stock mitre gauge. Building a crosscut sled is the first table saw project in any serious shop. A taper jig cuts angled legs repeatably. Jigs convert the table saw from a single-purpose ripping machine into the most versatile tool in the shop.
The Router & Bandsaw
The Router
Handheld routers profile edges, cut dadoes, and follow templates. A router table mounts the router upside-down under a flat table — safer for small pieces. Flush-trim bits with a guide bearing follow a template exactly: the basis of pattern routing for all curved components. Always feed against bit rotation for conventional cuts.
The Bandsaw
The bandsaw cuts curves that no other power tool can and resaws thick planks into thin veneers. Blade tension: correct tension gives a clear, high-pitched ping when plucked. Guides: set thrust bearing and side bearings as close as possible to the blade without touching. Feed rate: let the blade cut at its own pace — forcing causes drift and blade flex.
The End-Grain Butcher Block
Mill rough lumber square. Rip into equal-width strips. Glue into a panel. Crosscut the glued panel into equal-thickness slices. Rotate 90° to expose end grain. Glue into the final board. Flatten and finish.
Success criteria: All glue lines are tight and invisible. Surface is flat across width and length (straight-edge test). End-grain pattern is consistent throughout. Surface finish is smooth.
Phase 2 Practice Exercises
12 exercises to build skill through direct application.
Jointer Flat Face
Joint 10 boards to a flat face. Check each with a straight edge across three directions.
- Jointer setup
- Consistent feed rate
- Flatness verification
Jointer Square Edge
Edge-joint 10 boards. Check squareness with a combination square.
- Edge-joint angle
- 90° verification
- Reference face use
Planer Consistency
Plane 5 boards to identical thickness. Target variation under 0.2mm, checked with calipers.
- Planer pass consistency
- Thickness tolerance
- Caliper use
Table Saw Rip
Rip 10 strips to identical width. Check each with calipers.
- Fence setting
- Consistent feed
- Width tolerance
Build a Crosscut Sled
Build a crosscut sled. Test squareness using the 5-cut method.
- Sled construction
- Squareness calibration
- 5-cut testing method
Router Edge Profiles
Profile 5 different edges using roundover, chamfer, and cove bits.
- Bit selection
- Feed direction
- Edge quality assessment
Cut a Dado
Cut a 12mm dado across the grain with router and straight edge guide. Test a shelf fit.
- Dado depth consistency
- Straight edge clamping
- Shelf fit tolerance
Resaw Veneer
Resaw a 50mm plank into 4mm veneers on the bandsaw. Assess thickness consistency.
- Blade tension setting
- Consistent feed
- Veneer thickness uniformity
Bandsaw Curves
Cut a curved template shape on the bandsaw. Sand to the pencil line.
- Curve cutting technique
- Feed control
- Template sanding
Blade Selection Test
Cut the same board with rip, crosscut, and combination blades. Compare surface quality.
- Blade type comparison
- Surface quality assessment
- Application decision-making
Full S4S Process
Mill one piece of rough lumber: joint face, joint edge, plane, rip, crosscut.
- Complete milling sequence
- Machine order discipline
- Final dimension accuracy
Snipe Management
Identify snipe on planed boards. Develop a strategy to account for it in workflow.
- Snipe identification
- Length allowance strategy
- Waste minimisation