Greetings. I’m making an arbor/trellis for my deck. I am using 4X4 cedar and 2X4″ ‘s to give it a really Arts and Crafts look. I was wondering in anyone had any suggestions on or success making a mortise all the way through the 4X4 to fit the 2X4 so I can have the 2X4 ends as decorative overhangs? I have used a router, and Jig saw but its very difficult with the thickness of the 4X4 to have the hole square and not over sized. See attached drawing. Help?
Many thanks
Paul
Replies
Paul,
I'd take a close look at the 4x4 first and see how square it is. It's gonna be hit and miss if it's twisted or out of square. But even if it is, you can come close to a good fit by laying out your mortise carefully first on one face. Transfer the lines around to the opposite face. Then transfer them the other way to that same opposite face. I'd split the difference in the transfer lines.
Then I'd take a bit and brace or a portable drill with a Speed-bore bit on it and drill through the laid out mortise area. Start with the edge of the bit lined up on the edge of the mortise and drill that hole halfway through. Finish up from the other face drilling back into the center again. This will prevent any unsightly tear-out.
It really will be hit or miss as to whether these two holes are gonna line up. But the alternative is to pick a face and just drill all the way through. Use a backer block then to prevent blow-out.
Once you have your top and bottom mortise holes in, then keep drilling the rest of the wood out in the middle. Once you've gotten out most of the waste, then you can start chopping the mortise out square from both faces in towards the middle. Keep your chisels extra sharp as that cedar will want to crush with dull tools. Good luck. Gary
Thanks Gary, I will try your method out. You're right about the cedar wanting to crush. Its soaking wet in the centre and seems to turn into fibres instead of smooth cut.
Cheers
Paul
This forum post is now archived. Commenting has been disabled