Using a set of Garden Texture trestle plans, I made up a jig on an old hollow core door. Knowing that I have to make at least 30 units up, I tried to figure out a way to make things go as fast as possible. Using two 4” wide x8’ cedar planks I had, I ripped one into 1/2x1/2 full length pieces and the other, I planed down to 1/2”. I made my jig per the GT suggestions but added two hinged flip down circular saw guides so the 1/2”sq uprights can be cut in place, laying full length pieces in the jig. This allows cutting all 5 uprights at one time and no mitering cuts needed beforehand. Once the first set of uprights are cut, the second set can just be slid up to the top of the jig as the angles are already cut correctly from the bottom cuts being made on the first set of uprights. The hinged saw guides also help align two of the cross braces in the correct position.
My process is to put 5 full length uprights in the jig with the tops just barely above the cut line at the trestle top. I then lower both cutting guides which hold down the uprights while I glue and pin nail the two cross braces that sit flush against the edges of the cut guides. I then cut the top and bottom of the uprights following the guide with my Ryobi battery circular saw. I then add all other bracing which I make first by cutting the planed plank to The specific lengths of each cross brace and X braces. I then rip each piece at the required 3/16” thickness. My future idea is to cut holes on the sides of the jig to fasten coffee cans in each hole at each and the fill those coffee cans with the correct length pieces of wood at that location. the jig should allow for trestles to be built pretty rapidly once the cans are filled up with supplies.
So I now have my jig made up for later in the year when I get to making them all up. I made two with the wood I had on hand and I’m pleased with how they came out. They are 32” tall and will carry the trains from my back outside basement wall to the outside area.