Quick way to cut Dentil from 1x4?

[Greg Di]

I've been asked to replace rotted wood exterior dentil molding (approx 20 l.f.) with PVC.

Fypon does not have a profile that matches the existing wood profile.

It looks to me that the original installer may have actually cut this stuff from a 1x4 on site back in the 60's.

The recesses are 1-3/8" wide and are 15/16" deep. It's not rocket science to cut in theory, but I cannot contemplate how to make the cuts with tools I have on hand.

Any ideas???

[Dancing Dan]

Dado blade, crosscut sled, stops. It's a lot to cut but since it's PVC you wont have to worry about it splitting.

[Greg Di]

Dado blade, crosscut sled, stops. It's a lot to cut but since it's PVC you wont have to worry about it splitting.

Dan, that was my first thought, but can you imagine trying to crosscut AZEK, in all it's floppiness on a table saw?????

[Kgphoto]

Probably easier to do with a radial arm saw and/or a sliding compound miter saw or a router mounted on a rail.

[jeffaah]

Dado blade, crosscut sled, stops. It's a lot to cut but since it's PVC you wont have to worry about it splitting.

yup...that or a radial arm saw.


How high up is it? If it's high and hard to see.....use a jig saw???

[Dancing Dan]

Dan, that was my first thought, but can you imagine trying to crosscut AZEK, in all it's floppiness on a table saw?????

Could you clamp something to it to stiffen it up? Set up some outfeed tables?

A radial arm saw would certainly be easier, but I'm assuming you don't have one, at least not on site.

Don't know how well a router would work.

[Greg Di]

Could you clamp something to it to stiffen it up? Set up some outfeed tables?

A radial arm saw would certainly be easier, but I'm assuming you don't have one, at least not on site.

Don't know how well a router would work.

Don't have a radial arm saw. ;(

I don't see how a router could work. It would radius the corners unless I routed it on edge which seems tricky, dicey, and difficult at best.

I can't fathom sitting there with a jigsaw. All those 90º corners to cut...yikes....

[vanderpooch]

Greg,

What about roughing it in on the slider in 6 or 8 or even 10 foot pieces, then clamping a couple together and doing a cleanup run with a router just for the bottom of the notches? That way you get nice, square sides and a nice flat bottom, without having to balance the router on the edge of a single piece. You could use a long flush trimmer so you don't booger up the sides. You could even gang cut the notches on the slider as well...

- Kit

[S. Donato]

greg

i like the router idea too. as for the curved corners your going to have to clean up the ones from any type of saw too - if your not cutting all the way through.

what i would try to see if you can cut it vertically with a miter saw or long router bit. maybe gang a bunch of boards together and clamp them so you can make less cuts and have it self support it better. vertical cutting with a router would be the way to go but finding a long bit may become the problem.

just an idea... what about trying to use two pieces of 1/2, 3/4, or 4/4 Azek make your teeth out of one sheet then glue and that to the other sheet.

what about using the prazi... serously just KIDDING!!! do not try that ;-)

[SteveC]

How about making a jig to guide a circ saw and cutting like a box joint in reverse. The stock and sled are stationary and the saw moves.
L shaped piece to stiffen stock and an inverted U with side guides to limit lateral width of cuts, fits over top. Index marks or pins for consistency.
Would draw it but not technically proficient.

[Greg Di]

After all this, I'm having an Azek mill shop make the molding for me. Only $145. Totally worth it.

Thanks!

[Kgphoto]

Greg,,

Please post a pic of the old and new.

[Greg Di]

Greg,,

Please post a pic of the old and new.

Will do...you just reminded me to contact the client.

Thanks!

[Bob Kovacs]

I dunno...... sounds like somebody needs a Kapex to make those dados......lol

[S. Donato]

After all this, I'm having an Azek mill shop make the molding for me. Only $145. Totally worth it.

Thanks!

smart move...