When I last left off, I had commenced the cut out for the support arms, hijiki. After the needed pieces were sawn, I used a 70mm kanna to clean them up, following the pattern of taking one face out of wind, squaring up an adjacent face, then the other, then the last face. After that, using my digital caliper to check and re-check, I dimensioned the pieces down to size, leaving them just a hair fat at @ 0.005″ oversize on the sides, and about 1/64th+(0.015″) on the vertical dimension. That leaves me enough room for a final light pass with the plane on the sides at final assembly, and enough extra on top to adjust for any inconsistencies in fit with all the parts coming together at one place.
Then I used a trim router to cut the housing seats, and followed that by paring the cog abutment walls with a chisel and guide block:
A bit more paring:
The completed half lap on the first piece:
Then a trial fit of the two pieces at the top of the post, which also allowed me to do a little scribing. As the top piece of the first ‘X’ bottomed out, I marked the meeting point with the front of the cog housing on the post face, a process repeated on all four faces:
After the router work to deck the housings, I completed their walls with some chisel paring work. Here’s the completed second piece lower face – it looks like it could have a starring role as a set piece for a Battlestar Galactica model:
Note the second piece has the 0.5″ square through mortises now roughed out. I used a hand drill and then a chisel to do the mortises. Here’s how the two lower hijiki look, on the bottom face, when they are lapped together:
Next post in this thread, I’ll show how the second ‘X’ is fitted up to the first. I might want to return to my other thread on ‘fun in triangle land’ (kō-ko-gen hō) before too long however.