Materials Required:
(1) 3/4” x 2 1/2” x 48” Hardwood board
(1) Rail rubber (14” min)
Tools Required:
Wood Glue
Contact Cement (3M77)
90 degree miter box and saw or Compound Miter Saw
Bandsaw or Table Saw or Compound Miter Saw (best/easiest way)
In order to determine the cut angle of my subrail, I needed to know the thickness of my table rails and the profile of my cushions. Olhausen’s AccuFast cushions are K66 profile, and I measured the rails on my table to be 1 1/2” thick.
To make a 1-1/2” rail, I bought a 48” long piece of 3/4” x 2 1/2” red oak from the hardwood section of my local Lowes. The board cost me $3. I’ve used red oak before, and while it is a pain in the neck to cut, it holds up well to abuse. I cut the 48” board in half, and wood glued the 24” boards together to make 1 24” x 1 1/2 ” thick plank. I clamped the entire length of the board, and used 2 nails on each end (about 1/2” from the ends) to make sure I got a solid joint. It doesn’t matter if any of the edges line up perfectly or not, the various cuts will take care of any bad edges.
