Barnsley Reproduction Build #12: Final Fitting and Draw Boring

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Blog entry by stevo_wis posted 01-04-2015 01:40 AM 1787 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 11: Diagonal Tenons Almost There Part 12 of Barnsley Reproduction Build series Part 13: Button mortises, Final shaping, and Bevels »

I wasn’t satisfied with the fit that I talked about in the last entry so I called my mentor Dick. Dick is the best sharpener, dovetail cutter, and jointer that I know, and he came over. The two sides went together but still had a gap of 1/16 in a couple of places. After a while, Dick thought that I needed a miter jack or we could make one. So we made essentially a guide that wrapped the work piece on three sides to guide a chisel. Shaving very fine amounts and pushing the chisel at an angle gives very good control and doesn’t require much effort. By matching the piece to the jack, and a little undercutting, we trimmed until the joint was as good as it could get. A dry fit looked much better but I won’t know for sure until the glue up happens.

The joints are going to be draw bored with 3/8 pegs. Drilling the mortise first, then moving the hole 1/16 towards the shoulder in the tenon will actually bend the peg and draw the joint as tight as possible. First I drilled all the mortise pieces with a 3/8 brad point in my drill press.

A dry assembly with all pieces together is next and the holes are marked with both a pencil and pressing down with the brad point to mark the exact center of the hole.

Finally all the tenons are drilled 1/16 closer to the shoulder.

Next will be final mortising, and final cutting.

-- Stevo

2 comments so far

View bunkymarie's profile


4 posts in 2773 days

#1 posted 01-04-2015 02:12 AM

Hey that Dick is a great teacher. I took my first wood plane class from him!

View Brodan's profile


503 posts in 2797 days

#2 posted 01-04-2015 03:54 AM

Stevo, looks good. Interesting pulling the joint tight with the offset peg hole.

Always learning. thanks


-- Dan, TN

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