how to cut round tenon on end of curved stock
I am looking for a cleaner way to make a wooden training sword. I want to create the handle separate and wish to join it to the guard with a mortise and tenon joint. The hole for the guard is easy, as I can drill it out before I carve it to shape. I am having a heck of a time trying to figure out how to make the end of the handle perfectly round, so that it will fit snugly into the guard. I could do it carefully with hand tools, but I am looking for a more efficient solution, as I will be making these for everyone in my school.
All of the homemade tenon jigs seem to rely on the stock spinning, but since it is curved, I can't stick it in a lathe to rotate. I attached an image of the handle. The red area is where the tenon needs to be.
The tenon needs to be 1/2" deep and 1 1/4" wide.
Also, I would prefer to be able to do this with the blade already attached, and only the guard not yet in place. This way, the blade can run all the way through the handle.
Last edited by saniel; 07-09-2014 at 04:05 PM.