Got busy on wood cutting and building. The bottom board that supports the uprights is angled at 110 deg. at the point. This supports all the uprights. On the original ones there was a 1/2" steel plate that both held the two side pieces together, and had another two steel brackets that went up to the coupler pocket for support. No steel on this one, so I decided to use a half lap joint at the points, and then Glue ( Titebond III waterproof ) and Screw for strength.
All lumber to be used is common 2x6 boards ( actual 1 1/2 x 5 1/2 inches).
Set the table saw miter to the 55 deg. mark ( 1/2 of the 110deg total ) and cut the cheeks to 3/4 inch deep, and a couple of risers for the router to set on.
Set the router with a flat bottom bit to cut 3/4" deep, and removed the bulk of the cut out.
Used the chisel to clean up the cut and sanded smooth. Did both bottom boards.
Glued and screwed the joint. Paid close attention the the screw locations so that they wouldn't interfere with the screwing and dowelling of the vertical pieces that will be attached on the top side.
Trimmed the ends, and laid out all the mounting locations for the vertical boards. Everything will be located in reference to the center line on the jig.
One of the big steps to this thing went well.
Stay tuned for more.
Edited 1 time(s). Last edit at 08/31/2018 09:09PM by dave2-8-0.