Peter T":jpkdd4qw said:
What's the best way to remove the scrap material from this size of D/T. I was going to try coping out most of the waste and then cleaning up with a chisel but this seemed too much like hard work so I just went for it from both sides with chisel and mallet.
This seemed to work OK except that, after chopping down so far, the last piece in the centre broke out, taking a chunk of the end grain at the bottom of the D/T. Obviously when the joint is assembled this won't be visible but I just wondered if this was normal?
By the way, the saw is fantastic, very flattering to my humble skills.
Thanks,
It's hard to avoid some breakout, but it can be minimised and rendered unimportant. Firstly, ensure a razor-sharp chisel - a lot of breakout problems with mallet and chisel are down to the blunt edge and excessive force.
Take very light cuts, through to about half-way and turn the timber fairly frequently so you're working from both sides and the leverage exerted on the waste that's coming away is minimal. When you get close to the line, start taking ultra-find cuts to ensure that teh wedging effect doesn't drive the chisel back past the line.
Any minor breakout you get should be in the centre fo the socket where it won't be visible and since end-grain doesn't glue well anyway and it's the sides of the sockets that do the holding it shouldn't affect the srength of the joint.