Here's those work in progress shots I forgot to post
I cleaned up the edges using a #7 jointer. They'd been knocked around quite a bit.
And the same for the ends. I used a LA jack for that.
WIth everything looking a bit more assembled, I used some test sticks to measure the width between of the rails. I could have measured this, but this was more accurate (I think!).
I then transferred the measurments onto the rails
I cut a couple of wedges, and then mounted the whole batch in the woodrat. Its perfect for these unusual cuts. Especially doing the whole batch in one go.
I'm checking for any mistakes - and the results are pretty good.
Cutting the other face of the mortice requires it to have a matching angle. I reckon a tenon saw and chisel is the best option. I'm using a marking guage to scribe my lines.
Making the cuts...
Next stage is a dry assembly - just to check everything
I want to round of the edges slightly so am using a router with a round over bit.
And the same thing for the rails. I'm using router matting which holds everything securely.
A bit of sanding before assembly makes everything much easier, and stops the glue drips sticking to the wood.
Final hand sanding
Everything taped up with masking tape.
Anyone else have this trouble?
Everything gets a coat of danish oil
Need to make the wedges next. Cut approximately on the bandsaw
You can see how rough they are:
Then smoothed on a sander ready for use
Regular PVA
Hammering the wedges into position - you can feel them "bite" and thats when I stop knocking them in!
Clamps on
Trimming then planing the ends.
More coats of oil.
Making the feet
Drilling the holes. I've left some slack to cope with the expansion of the wood against the long grain of the feet
End grain shavings with a spokeshave - lovely!
Trimming them up a bit...
Smoothing them relative to the ash sides.
Touch more sanding...
And fini!