Ouch, I cut a mortise on the wrong side of a leg to a garden bench. The mortise is .75 wide, 1.5 deep, 3″ long in a 2.5″ square leg by 40″ long, a lot of white oak to toss. The mortise was cut with a Forstner bit and still round and rough. I can’t imagine getting it square enough to insert a filler and sand smooth. Pic attached.
Anyone have any advice? Thanks. 🙂
Replies
I feel your pain. Any way this would work as the other side leg (assuming you haven’t cut it yet?
1. You could square off the ends and insert a square piece of wood. As long as it glues reasonably well on the surface, that is all that matters.
2. Assuming the mortise is in the proper location, you could cut off say 1/8” the entire surface and put a a “Dutchman” type patch.
3. If mortise on the other side is in a different location you could do step 1 then step two.
4. Save this piece of wood for a future project and remake the let.
5. Make this a feature with complimentary wood and do also to the other leg.
Good luck.
It shouldn't be difficult to fix that if you are careful and take your time.
I make these mistakes pretty often, and it's so frustrating... WHY can't I remember things...
I take my time checking and selecting the best matching piece from scraps, and then I cut it into a square. It doesn't need to be perfect. I just take it to the bandsaw and make a small square by eye.
Then, cover the hole with it. Trace it.
Router to hog any mass out, and then your sharpest chisels and carefully and slowly take the edges back until it's a real snug fit.
If you take your time you'll be the only one who can ever notice.
Too late to make it a through tenon? Have you cut your cross pieces yet? Wedged through tenons are sweet.
I'd make it a through tenon as well.
Another vote for through tenon here!
Square up and smooth out the long sides and leave the ends rounded. Then make a plug to fit and round the ends to fit. Glue it in and cut/sand it flush.
Wow I thought I was the only one who made that mistake. I keep two around as reminders to check twice, cut once. You are not alone.....
Ha, well I will look at squaring it up and patching it or a through tenon. I didn't think of making the plug, tracing around it, then chiseling. I was thinking in reverse, making a plug to fit the hole, sounded nearly impossible. I have plenty of matching wood from other mistakes. Thanks all!
Consider making your plug SLIGHTLY tapered (chisel, plane, or disk sander). Then you can gently tap it in when you glue it.
Good idea, thanks!
Similar dilemma last year... hinge cups were drilled on the wrong edge of a cabinet door. I used a router & bushing kit from Rockler:
https://www.rockler.com/inlay-bushing-and-bit-with-removable-collar
I made an organic shaped template and the patch has to be looked for to see it. I got the grain match as close as possible, yours should be pretty perfect if you go this way. The second image is contrast enhanced to make it easier to see.
I can see your fix if I look, which I was, it is not at all distracting, which is suitable many times. You did good. Some things have to be perfect, some not. Thanks for sharing an example and tip.
Me again, I like this method you provided. I get to spend just a little money, not a lot. Looking on youtube for some examples. Thanks.
_mj_, just wanted to let you know your advice worked great. It took a little practice but I also learned something. Ovals are easier than rectangles. I could have aligned the grain better, again, I learned something . Thanks.
Awesome!
Looks great! How thick did you make your patch?
Follow up to let us know how it holds up out in the garden.
3/8", thinner ones at easier. Thanks!
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