Serving Tray - part 3

[oldhudson]

In Part 2 I showed how I used the wrong bearing and as a result had to go back to square 1 to mill new side pieces. In this section I'll show another mistake and how I patched the part rather than replace it. In cutting the grooves this piece caught on the edge of the table saw insert instead of the fence resulting in a out of position cut.

I thought it would be easier and faster to patch this mis-cut groove. I dug through the off-cut pile looking for stock with the right grain character. Then I cut a thin section of this stock and continued forming it with the plane and a dovetail saw. Here's the patch before putting it in place.

I glued it into position, because I couldn't use a clamp so I pressed it into position with couple of shims. I used paraffin wax on these first so glue couldn't stick to them. Then I used a chisel and sand paper to finish fitting the patch.

The repair completed I cut the splines which will add glue surface and strength to all the end joints I'm gluing together.

Like many woodworkers sanding is the least favorite step, but gluing often gives me heart burn. I dry fit all the splines for this project. I made several small adjustments paring grooves sizes with my sharpest chisel and sanding the splines for better fit still.....it took about a half hour to get one end glued.   Here it is glued and clamped. I used the square to ensure the ends would be square to the sides.

Edited July 8, 2015 by oldhudson

[amazingkevin]

Nice repair! Your wood working experience came in very handy here.!

[Phantom Scroller]

Loads of work for a serving tray but very good work. Roly