It’s good to sit down at the keyboard after a full day working on the sawhorse project. Now, I know, I know, there’s no shortage of people who will tell me that they could build a sawhorse in a few hours so what am I wasting my time on?! Just slow I guess….
Today’s work comprised the final stage in the frame joinery cut out on this 19 century French puzzle – the cutting of the mortises for the interior x-braces. I used a jig and my router to rough out the mortises, and then trimmed them to the line with various chisels. Here’s the result, showing a pair of upper mortises and a couple of lower mortises:
With the mortises done in a couple of hours work, I commenced the fitting of each pair of lapped interior braces:
Once both sides were done, it was time to do an assembly. This proved to be one of the most difficult things to assemble I have ever dealt with, as so many parts have to engage together at once. With enough patience and eye-balling, it was a matter of a little bit here and a little bit there, tap-tap, nudge-nudge:
I then placed a stick, one of the long braces that went by the wayside in the build, inside the frame to check how well aligned the brace sets were, and to my satisfaction the stick sat exactly upon all four intersection points at once with no rocking – I was a little surprised actually:
The sawhorse isn’t quite complete yet – I need to spend a little time fiddling the fit a bit more, and then assemble it for a final time, with glue and wedges in some of the tenons. Then I will fit a 3/4″ sacrificial cap, possibly of mahogany (I’m not quite sure yet what material I will choose), with sliding dovetail keys and a transverse capture pin somewhat like my other sawhorse. Those steps will be covered in the next (and final) post in this series. Thanks for coming by today – I think I’ll go and have a beer!
–> Go to post 30