1x6 into a 4x4?

[Dave N]

Perhaps this question has already been asked somewhere on this forum but I wasnt able to find it after an hour or so of searching. Is there a recommended length of Kreg screw to use when combining a 1x6 into a 4x4 post. I have seen a few conversion charts and what not on the page but nothing goes up to a 4x4 post. 

Building a dinning room table and dont want anything coming out after I deliver it to a friend. 

[Ken Kortch]

I assume that the pocket holes will be in the 1x6, and the sharp end of the screw will be entering the 4x4. If this is true, then you'll want to set the jig height and drill bit stop for the 1x6 thickness (0.75 inch).

Not sure where the 1x6 is along the 4x4. If the 1x6 is flush with the outside and the pocket holes are on the inside, you'll need to be careful with the screw length - otherwise it will exit out the side of the 4x4. The length should match the 0.75 width - as if you are attaching to another 1x material.

If the 1x6 is in the middle of the 4x4, then there is not much concern about the screw exiting the side. I think it could be quite long.

The best thing to do if possible is a test run with the materials using scraps.

[Dave N]

I am actually screwing it into the middle and attempting to make it flush with the 4x4. I used your suggestion of trying it out on some scraps with various screw lengths and ended up using the 2 1/2 screws and it actually went just fine. I got it to be flush and very secure into the 4x4 with that length. The original 1 1/4 length screws just weren't really holding it as secure so this definitely works. 

Thank you for your help!

[Ken Kortch]

If you were using a 2x6 instead of the 1x6 I might suggest using the Kreg HD Jig with its bigger (stronger) screws. I'm a big fan of the HD Jig! 

The regular 2-1/2" Kreg screw is a #8 gauge (about 3/32" thick), but the HD screw is a #14 gauge (about 1/4" thick, and 2-1/2" long) - MUCH thicker and stronger. 

[Edward Weitsman]

My 2 cents... I would not give up on a nice and thick layer of a wood glue in the joint... This with 2 1/2 " screws will make that joint stronger than the wood itself. 

Dave N said:

I am actually screwing it into the middle and attempting to make it flush with the 4x4. I used your suggestion of trying it out on some scraps with various screw lengths and ended up using the 2 1/2 screws and it actually went just fine. I got it to be flush and very secure into the 4x4 with that length. The original 1 1/4 length screws just weren't really holding it as secure so this definitely works. 

Thank you for your help!