Wooden Link Chain From a Solid 2x4

Decided to try making a wooden chain from a solid piece of wood (specifically, 2x4). It turned out pretty neat!

Expect elaborate router table jigs ahead. You've been warned.

Starting with a 2 foot section of 2x4.

Construction grade lumber is quite rough, but that's nothing the orbital sander can't fix!

Just two cuts with the track saw.

Actual dimensions of the resulting part are 1.5" x 1.5" (and 2 feet long)

Requires a total of 8 cuts at partial depth (2 on each of the 4 sides). This would be easier on a table saw, but I don't have one.

Since the track saw cuts aren't end-to-end, I cut the ends off at the mitre saw to release the shape.

A router plane cleans up the "plus" shape, accompanied by a little sanding.

Cut vertical slots at even spacing, and alternating sides.

This required quite the router table setup to safely make the cuts.

Make symmetric cutouts around each vertical slot from the previous step.

Drill holes through the remaining connections so the links can be separated.

The chain is beginning to take shape...

A fret saw is used to trim away what's left of the connecting material, the parts drilling couldn't remove.

Round the corners, chamfer the edges.

Now I could spend hours playing with this thing... Thanks for reading :)

Here's my video the build :)