easy wood projects
The next sequence of steps I used are similar to those use to assemble the under carriage attached to a chair. Im using double locking wedges which would probably hold the tenons in place without glue but since I have the glue Im going to use it for added insurance. On a chair I would use hide glue because it is forgiving and holds more than adequate. If I ever wanted to repair the chair it would be a lot easier to take apart and repair using hide glue but for this bench it will see quite a bit of abuse both indoors and outdoors so I decided to use polyurethane glue. I do not wet the joints since I live on the pacific coast and everything is pretty well wet anyway. I have done some bent lamination s that I wanted to be both water proof and flexible and so far they have held together with no fasteners. Also since this glue expands I wanted to experiment and see what it did to the locking mortise and tenon joints and also the wedges.
1) I hammer in the legs with the orientation so that when the wood in the legs expands it will not split the bench. I then mark the tenon to where it exits the seat.
2) Here I cut the slots in the tenons for double locking wedges 2/3 of the way from where the tenons enter the seat. I also measured and shortened the legs so the shave horse will be a bit over 20" from the ground. I also shortened the tenons so they only protrude about a 1/2" above the seat. This is enough and will prevent problems when driving the wedges. You want to use an appropriate saw to do this work. I have used a Japanese pull saw but my old Disston is sharp and has a nice thin kerf.
3) I used a file to open the top of the mortises in order to allow for the locking tenons to expand.
4) I used a tooth brush to spread the glue on both the mortises and tenons. I do not put glue on the ends of the tenons. After the glue is applied I insert the legs in the proper orientation and hammer them home.
5) I apply glue to only one side of the wedge to allow for wood movement and so the glue bond on one side will hold fast while the other side can move so as to not break the glue bond when the wood moves.
6) I hammer the wedges home with a steel hammer. Have extra wedges ready in case one breaks you can use another to continue driving the wedge.
Now it is time to let things dry. I did not use clamps since the weight of the bench is putting weight on the mortises and the locking wedges are expanding them. As you can see from the pictures the glue begins to react just from the moisture in the wood which also gives me a little extra work time before the glue starts to set.
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