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This blog is written by TungOil | 51 entries so far

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Greene & Greene Gamble House Side Chair #24: Plug Locations and Square Holes- Part 2

06-06-2018 01:54 AM by TungOil | 7 comments »

With my plug locations established, I move on to drilling the holes and cutting the square plug holes. I set up stops on the drill press and drill the clearance holes in the front legs, back legs and crest rails. There are 27 square plugs on each of the 15 chairs, for a total of 405 square plugs. After all of the clearance holes are drilled, I cut the square plug holes using the Lee Valley square hole punches. I align the punch with the hole using a long dowel pin, then square the punch with a saddle square. A spare loose tenon inserted into the mortise helps keep the mortise wall from collapsing as I cut the square plug hole. It takes about 12 hours to cut 405 square ...

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