Milling boards into 4 square lumber

Most lumber yards only sell finished boards, lumber that has been planned to remove the rough finish left from sawing at the mill. This lumber is sold in finished sizes so a 2x4 is actually 1-1/2 x 3-1/2 inches. This can be a huge time saver for anyone using this boards but it also comes at a price. Finished lumber is more expensive then rough stock and can make a larger project very expensive. Your wood working plans will show sizes as rough or finished so be sure to check before buying stock.

Like all things you have to pay more for finished boards as opposed to rough lumber. In same cases this can be substantial. So it only makes sense to try and get boards that is rough. This is lumber that is fresh off the mill. It has not been planed to a finished size and the surface isn't smooth like finished lumber.

Step 1: Cut your stock to rough length

The first step I take to to rough cut the stock to length. The length is a rough dimension. This way I only have to plane the stock I am preparing to use and avoid wasting other stock. I simply use a circular saw and a combination square to make the cuts. The ends do not need to be perfectly square since I will have to trim them to the finished length I need.

To avoid un-usable wood and the potential hazard from splinters it is always good practice to cut and loose knots and cracks from the rough stock before you start to plane it.

Step 2: Planning one face flat

Analyze the boards to determine the direction of the grain and whether there is cupping. It is best to place the cupped face down since it will sit better on the jointer table.

Set your jointer to remove only 1/32" at a time. This will make it easier to pass the lumber through the cutter and your jointer will not have to work as hard. Keep making passes until the rough surface has been removed and the face is perfectly flat.

Step 3: Square one edge

Adjust the table on your jointer so it is exactly 90° to the table. Again you have to look at the grain of the wood and feed the board through so the direction of the grain is coming out of the wood. This will give a cleaner surface and avoid tear-out.

Keep feeding the stock through checking after each pass with a speed square to make sure the edge is square to the first face you planed flat.

Step 4: Rip the stock to the rough width shown on your plans

Over at the table saw to rip the board to its rough width. This dimension will be about 1/16" wider then the final dimension. Simply run the stock through the table saw and and then go back to the jointer to clean up the edge and remove any saw marks. You will need to run the board through twice to remove the 1/16" of waste.

Now your board should have two finished edges parallel to each other plus are square to one face.

Step 5: Planning the other face

The next step is to true the last face and make it parallel to the first and square with the two edges. This is done at the thickness planer.

To plane the second face I use the thickness planer. It will plane down this face to my desired thickness and make it exactly parallel to the first face I planed on the jointer. I set my thickness planer to remove 1/16" at a time. It is important to measure your stock and determine the thickest point. Sometimes rough stock can vary in thickness and you shouldn't assume it is a specific thickness. Place the finished face down on the thickness planer table and continue to feed it through the planer until you achieve the thickness you need.

Conclusion:

Many of the woodworking plans that you use will have tips and advice that will help make it easier to complete that specific project. They also often recommend certain tools they use to make the cuts. This is a big help especially for those with less experience. The 5 steps above are easy to follow and can save you a bunch of money by helping you avoid finished lumber at the lumber yard.

Always remember to read and follow the directions that come with your power tools. This will provide safety information as well as tips and techniques on how to use the tools more effectively.