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First Build - And May My Mistakes Be Minimal

No kidding? I don't run into too many DBAs in the wild unless I am trying to hire one. Good ol' Business Continuity--I am well-versed. I am in the health care industry now after 8 on the financial side (Merrill Lynch, IBM, etc). It is nice to be with a smaller company now. Step 1: Think of a repeatable process. Step 2: Automate the process. Step 3: lutherie research.

;)
I am feeling right at home here. I am a Citrix Architect by trade and have applied the same sort of methodology to my builds that I employ at work. Do research, lab it up and test, and eventually come up with a SOP that can be applied repeatedly.
 
So I built a jig for my mitre saw and put a good crosscut blade on. Joint is not as even as I'd hoped so I've got some scraping and sanding to do to get it right.

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The headstock wings will cover the sides of joint, but I have some small "waves" on the surface of the cut end. It's time to walk away for the day before I make things worse. :)
 
I'm a bit concerned here. I think I may need to belt sand the cut end to get it even. I dry-clamped and definitely cannot get it flush (2mm gap clamped). Do I need to make a sanding jig with correct angle or can I just go for it and try to work it to an even surface on the belt?

Vague description I know... I am hoping to make it work, but do not want to work the cut in in futility if I have already screwed it up by somehow not cutting correctly.

Edit: could not get it flush right away. Maybe just need more elbow grease.
 
I'm a bit concerned here. I think I may need to belt sand the cut end to get it even. I dry-clamped and definitely cannot get it flush (2mm gap clamped). Do I need to make a sanding jig with correct angle or can I just go for it and try to work it to an even surface on the belt?

Vague description I know... I am hoping to make it work, but do not want to work the cut in in futility if I have already screwed it up by somehow not cutting correctly.
Do you have a jointer? If it were me I would glue up a test piece and give the jointer a try.
 
Theoretically, even if I take more wood off the cut end, as long as I remain parallel to the angle (re: on plane), I should be fine. Looks like I am a tad high on one side of the cut.

That means that I was not able to complete the mitre cut all the way through. This was due to my jig being too tall and the blade guide catching before the blade was totally flush with the board. So it cut through, but did not cut through the angle completely. Round blade, square board.

So, I will go to the jointer in the morning.

Ensure squared jointer fence. Hold cut end of scarf tightly to fence, and level out the problem area.

If I am successful, I'll remove the high spot and be able to sand lightly to achieve the joint surface I need.

Best case, I have a scarf that may require a veneer headstock face. That's actually ok by me since I'll need to glue headstock wings which will hide the joint on the sides. A bit more work will b required to further thickness said headstock, but I will figure it out as I go.

Notes for those paying attention to my ramblings:

Mitre saw motors are usually on the right. They will contact a tall jig. Build it as low as possible as well as make the arm that you clamp the neck to long enough to keep clamp clear of all saw action.

Keep in mind the blade guard. It will guide just fine unless a clamp gets in the way.

Use a good crosscut blade! They are designed for small kerf and little tearout, if any. With these blades you must cut slower! This ain't framing for a barn!

Finally, keep things tight. You don't want your neck to be wiggly in the jig. It took some testing, and if you go too fast, wood will fire out the back of your saw and it is not a pleasant sound. Be safe always!
 
A jointer sounds like it will tear up the knife edge on one piece or the other. I've seen other people double stick the two pieces together with both glue faces down and sand them as one unit, which cancels out any tiny errors. I've had the same problem with a crosscut saw, made an elaborate jig and then realized it won't clear the motor. D'oh!
 
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I've never done a scarf joint so take this with a grain a salt, but I don't think I'd use a chop saw to cut it. The table saw would be my first choice. Or a router using an angle jig might be my second. I have a pretty good chop saw, but I've found there's a little too much "slop" for me to trust it to be right on. It's fine for cutting 2x4's, but not much more than that.
 
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Do you have a small hand plane? I'd suggest using this instead of a power tool to square up the joint- you will have way more control, and less likely to damage the outside edge where the wood gets down to mm thickness.
This approach is always best. Definitely slower but the control is fantastic. I have seen many projects going along perfectly then one quick cut destroy it entirely.
 
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I planned on using scrap to test the jointer theory. I should have mentioned that first! :)

Thanks for the small planer advice, I will pick one up today. The one I have is way too big for this. Stacking the angles for sanding also sounds like a good plan.

Again, it is so cool to have such a wealth of knowledge here. I would not be embarking on this interesting journey without the LC!
 
Hey Rich, here's one of the little guys I picked up to fine tune my scarf joints.

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Home Depot has them too. You might want to do a quick sharpening of the blade first, but for a small fine-tuning like your scarf angle this should get the job done.

Lonnybass