l
F.8L Falco Construction Manual
10–3
Revision 4, March 1, 2002
Making a Scarf Joint
Every builder ends up using his own version of a scarfing jig. There are a huge number of such
arrangements and these are shown in the many reference books listed in Appendix B.
Figure 3
The simplest way to scarf plywood is by sanding with a drum sander mounted on the back of a
radial arm saw as shown in Figure 3. To provide clearance for the motor, you will have to make
up a raised table. Make up a gauge block from hardwood with a 15 to 1 slope. Every time you
make a scarf joint, you can use the gauge block to set the angle of your sanding drum.
The board used for the top of the raised table should be a constant width, say 8 inches. For a
straight scarf, a straight strip of wood can be attached to the plywood with small nails. This strip
of wood will serve as a guide as it will rest against the edge of the board that is the top of the raised
table.
The table will have a short fence on one side so that it will guide the plywood by the sanding
drum. You need to cut an opening in the fence for the drum. This will be used for free-hand
scarfs.
There are a number of variations of this sanding drum scheme that do not involve a radial arm
saw. The sanding drum is usually mounted on an electric hand drill or an electric motor. This is
mounted on a table (with a fence as before). You can also use the table of a table saw. The
sanding drum is mounted on one side. The motor is hinged from the table, and the angle adjusted
with a turnbuckle. A strip of wood tacked to the plywood is used to guide the plywood. The strip
of wood fits in the table guide groove in the table saw top. (See “Shop Notes” in Tony Bingelis’s
The Sportplane Builder
for such an arrangement.)
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