Time for the Mortise and tenons.
First of all, thanks to all who gave me advice about the mortising machine from the last blog. I did hone and tune the chisel and mortise machine and it did cut considerably better. I also turned the chisel so that the open side faces the previously bored section and didn’t have any trouble with chips getting stuck (thanks Betsy!)
So I made the layout lines on my legs:
And cut the mortises. Notice the stop block for repeatability:
I was wondering how I would go about cutting the tenons. I decided to just do it the “easy way” and cut them on my radial arm saw (I love that thing.)
It takes a little while to hog out the waste with a thin kerf blade but there is almost no set-up time. Call me lazy but it works for me. It would have taken me just as long to set up a jig for my router or whatever other method.
A roughed tenon:
I made marks 1/2” from each edge of the tenons:
And I cut the notch out on the bandsaw (what is the correct terminology for this part of the tenon?):
I spent quite a bit of time chiseling the tenons…
...and cleaning out the mortises:
I also used my “Record” low angle shoulder plane to fit, smooth, and square up the tenons:
The finished tenons (aaahhhhh, at last.)
Finally, at 2:00 AM in the morning (on my Birthday!) I dry-fit the joinery. I didn’t start until after work last night.
And it looks exactly like it did at the end of the last section :( But I know that a big part of the work is done :)
I will disassemble it and do all the shaping (leg tapers and arches) before gluing it. But I had to see how it all fit together. Geez, that wood is nice, isn’t it? I never took Birch seriously before. I always used it for making jigs because it is hard and relatively cheap.
This phase took about 5 hours. Total Project Time So Far: 10 hours
I have the day off tomorrow. Check back later… I expect to make quite a bit more progress (after I sleep in).
-- Happy woodworking! http://www.openarmsphotography.com