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Meeting Rail Replacement

Posted: Fri Jan 18, 2019 8:02 pm
by johnleeke
(update: 6/16/19, details on blank stock)

It would take at least two hours to repair the rail, so I decided to replace it with a new one since that would take less than 45 minutes.

1. Assess Conditions
Weather checks
Catch screw holes
Ring checks
Broken tenons
Decision: Repair the rail, or replace it?

2. Select Wood
Heart wood, more growth rings per inch, avoid defects
Rough out blank

3. Measure & Document Profile

4. Rip out Rail Stock
Bench Saw (Table Saw)
Make it a bit oversized in thickness, width and length
Then flatten if need on the joiner, rip to final width, thickness, and cutoff to final length

5. Layout Joints
Joint design
Marking cheeks
Slope of bevel
Ends of cheeks
Carry the squares
Mark cheek sides
X out waste

6. Cut Joints
By hand, back saw, coping saw
Chop mortise by hand, chisel & mallet

7. Assemble
Check for squareness
Peg the joints