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Rough cut on bandsaw, followed by clean-up cut with blank clamped to a holding fixture on chop saw.

Perfect about 8 out of 10 times.

Tidy-up with Japanese hand plane, if necessary.

Yes, looking back on this thread, it sounds like John's method is more accurate, and I would trust his experience more than mine. I didn't know a thing about building guitars until 4 years ago. Our method is good for our purpose since it's quick, but it can leave a ~1/32" gap at one of the corners -- we just clamp the gap closed, but I imagine many of you would want better. Except for that corner, the overall surfaces do come out flat. I'm going to try John's method, too, and we may switch if it's fast enough.

6strings, I'm not exactly sure what you're describing. Are your surfaces flat? We do get saw-marks in a semi-circular pattern, but as long as our feed is slow and blade is sharp, these are pretty faint, and haven't interfered with glue-up.

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David Malicky

Hi

I am approaching the point when I need to make this joint, I think I will try all three methods on some test wood first.

Band saw
Table saw
Manual cut

Has anyone ever raised table saw into the neck to make the cut, seems scary to me ?

John