Need Help Finding a Router Bit - Page 2 - Woodworking Talk - Woodworkers Forum
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post #21 of 22 Old 07-15-2013, 01:42 PM
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We're talking about a mortise 3/8" deep and 3/4" long and 1/16" wide.

Go to HD and buy a "Buck Brothers" brand chisel set. (About $30?) Use the 3/4" to mark the sides of the slot. (Nice crisp edges) Take the 1/4" chisel and carefully grind it to 1/16". (Don't burn the chisel on the wheel, stone or belt sander.) Now chop out the mortise for the penny.

Use a 16d nail and propane torch. Heat the nail and flatten to 1/16" thick. File to shape, 1/16" x 13/32". Use the torch to heat the nail and burn your way in. When you're done, sand off the scorch marks.
You could do the same with a penny but grind the edge so that the "rim" doesn't make the mortise too wide.

With the 16d nail and torch, you could try to make a 1/16" wide scraper. Heat the nail, shape the nail, sharpen the scraper, heat again, plunge cherry red into motor oil to cool and then sharpen again. Hold against a straight edge and scrape to 3/8" depth.

Talk to your dentist and get an old burr. In a Dremmel you probably could work the wood to cut the slot. This may take a lot more skill than any of the above.

Use the right tool for the job.

Rich (Tilting right)
Huntington Beach, California
Remember that when we have the "BIG ONE" everything east of the Rockies falls into the ocean.
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post #22 of 22 Old 07-31-2013, 09:09 AM
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How about using an oscillating tool to cut the slots straight in? If the blade is too wide you could modify the width to suit the dimension needed.
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