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  • Woodworking Repairs and Fixes, Pt. 2: Mechanical Mistakes
    		•
    From "Wood Works"
    episode WWK-513


    PHOTO

    Mortises cut in the wrong place can be fixed by gluing in a tenon, flushing the surface smooth and starting over.
    In this episode of DIY Wood Works, host David Marks offers some of his simple fixes for common woodworking problems. This segment features repairs to wood caused by mechanical mistakes such as misplaced mortise and power-tool slippage.

    Materials may include:

    Band saw
    Yellow woodworker's glue
    Scoring knife
    Plunge router
    Hand scraper
    Block plane
    Chisel
    Sandpaper, various grits
    Straight-edge
    Carpenter's pencil
    Woodworker's tape
    Clamps
    Safety glasses or goggles
    Protective gloves

    Safety Alert: Always wear safety goggles or safety glasses when
    working with wood, power-tools, saws, drills, routers, etc.
    advertisement


    PHOTO

    Figure A
    PHOTO

    Figure B
    PHOTO

    Figure C
    PHOTO

    Figure D
    Every woodworker, no matter how experienced, will eventually make some mistakes. How well a mistake is repaired or concealed is a sign of the skill of the craftsman. Here are some methods for repairing some of the most common mistakes.

    Repairing a Misplaced Mortise

    If a mortise is cut out of proper alignment (figure A), a simple fix can result in a repair that's just as strong as the original stock. The fix is to simply glue a tenon or plug -- made from the stock -- into the misplaced mortise.

    • At the band saw, cut a tenon that's slightly taller than the depth of the mortise that's being repaired.

    • Apply glue to the tenon and mortise, and fill the "unintended" mortise with the tenon (figure B).

      Once the glue has cured, flush the exposed part of the tenon flat using a block plane (figure C) and a hand-scraper.

      Now the stock is repaired, and you can go back and make layout marks for the new mortise in the proper location (figure D).


    PHOTO

    Figure E
    PHOTO

    Figure F
    PHOTO

    Figure G
    PHOTO

    Figure H
    PHOTO

    Figure I
    Repairing a Simple Router Error

    Router errors can happen for a number of reasons, such as a hand slipping or stepping on the cord by accident. Here are some simple fixes.

    • If a router slips while cutting a channel for an inlay (figure E), simply go back and cut a wider channel and increase the width of the inlay.

      Tip: To accommodate potential repairs like this, it's always a good idea to wait and cut the stock for the inlay after routing the channels.

      If the router-bit slips while making a recess for a hinge (figure F), a repair can be made using a scarf-joint inlay using a piece of the same stock.

      Outline the area you want to patch, then use a sharp chisel to scribe the boundaries.

      Use a plunge router to route out the recess.

      After cutting out the wood patch, apply yellow glue to the recess (figure G).

      Tape the patch in position using carpenter's tape (figure H). Add a caul and clamp to secure the piece and allow the glue to dry.

      Once the glue has dried, use a block plane to flush the edges patch with the smooth.

      Use a chisel to square the edge of the mortise.

      If the wood for the patch is a good match, the repair can appear almost seamless. You're now ready to install the hinge (figure I).

    In the segment that follows, David Marks offers tips for avoiding tear-out when cutting plywood.


    RESOURCES :

    The Small Wood Shop (The Best of Fine Woodworking)
    Author: Helen Albert (Editor)
    Publisher: Taunton Press
    ISBN: 1561580619


    Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
    Author: Editors of Fine Woodworking magazine
    Publisher: Taunton Press
    ISBN: 1561583456

    David Marks Website
    David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com

    Fine Woodworking
    A magazine devoted to high-quality craftsmanship in woodworking.
    The Taunton Press Inc.
    Website: www.taunton.com

  • ALSO IN THIS EPISODE:
  		• Woodworking Repairs and Fixes, Pt. 1: Natural Flaws
  		• Woodworking Repairs and Fixes, Pt. 2: Mechanical Mistakes
  		• Woodworking Repairs and Fixes, Pt. 3: Mistakes of the Hand
  		• Woodworking Repairs and Fixes, Pt. 4: Plywood Tear-Out