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I roughed out the legs. I set up a quick great bandsaw table for cross cutting large thick components... too big for my table saw and chop saw. It has a full miter slot and cuts real square.
The only short coming of my Aggazzani Band Saw is the shallow miter slot and like most bandsaws sometimes the table is not big enough... short for cross cutting with no leading table forward of the blade. The table extension adds 8" in front and 24" on the right. Which gives a lot of support when added to the existing table. Two clamps secure it... it really only takes a couple of minutes to install and less to remove. There is a built up edge that drops into the gap between the fence rail and the table and another on the side... a clamp secures the dropped edge to the cast iron table. My outfeed stand levels the edge to the right.
I shaped the legs in pairs after cutting curve on bandsaw. Then I made the mortises on the MM slot mortiser and set up the base dry to check everything...
I tried with a chair and moved the long stretchers (beams) in for knee clearance.
These mortises are cut with the Festool router a spiral and a nice set-up using the guide rail... setting 2 stretchers together... squaring the guide rail and moving the router back and forth lowering each pass a bit.
The yellow tape sets the limits...Top of the leg shows the nice fit got on the fascia infill pieces... the grain almost continues. Q. How is that guided rail system on the router for speed, accuracy, and repeatability? I've been considering one to release me from the tedium of making full size templates unnecessarily. I have the MM slot mortiser on my Elite S and that handles most situations. The Festool router with the guide rail is very good. It depends how well you set it up of course. I find it more accurate then most templates I have made... and I have made many and still do for many things. If things are a touch off, I sand or rasp the tenon then number them and put an arrow on for up... that way the sets are matched and you know at glue up everything fits just right.
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