Old Methane Gas Cloud
Join Date: Jun 2009
Location: Huntington Beach, California
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.