Spindles and rungs on chairs are easily broken. Follow these simple steps to fix a broken tenon or create a new rung, if repair is impossible. Materials:
Saw
Dowel with same diameter as the tenon
Drill press and bits
Wood glue
- Using a saw, cut the broken end of the tenon from the rung so that you have a smooth edge at the end (figure A).
- Determine the diameter of the end of the tenon you just cut. Choose a dowel of the same diameter.
- Using a drill bit the same size as the dowel, drill a hole in the cut end of the rung (figure B).
- Pour wood glue into the hole you just drilled (figure C).
- Screw the dowel into the hole, and allow the glue to dry (figure D).
- Replace the rung in the chair.
Creating a New Rung If a tenon cannot be repaired, it's easy to make a new rung. A router table with a special fence is the tool of choice for this project. Materials:
Two 14" x 9" pieces of 3/4" plywood
Drill
Dry-wall screws
9" x 2" scrap piece of 3/4" plywood
Rabbeting bit
Router
Router table
Clamps
Dowel
- Use drywall screws to fit one piece of 14" by 9" plywood perpendicular to the second piece (figure E). This creates a V-block fence to use on the router.
- Cut the scrap piece of plywood so that it fits like a shelf inside the V-block (figure F). Drill the shelf into place.
- Put a rabbeting bit in the router, and raise it until the bottom of the bit is even with the top of the router table.
- Place the V-block fence on the router table, positioned so that the router bit is in the center of its joint (figure G).
- Clamp the V-block into place on the router table's fence.
- Turn the router on. Holding the dowel in one hand, lower it through the shelf on the V-block and into the rotating bit (figure H).
- Rotate the dowel clockwise with the other hand. Keep turning until you've cut a tenon in the end of the dowel (figure I) to create a new rung.
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