I'm working on an oak dining table (see below for some specs), and I was planning on using metal corner braces and bolts to draw the legs up against the apron. I was not planning on using any mortise and tenon joint, just the brace and bolts; like this, but with two bolt holes: http://www.rockler.com/product.cfm?page=782
However, I'm having some issues.
1. First of all... can I get some tips on drilling the holes accurately? This probably seems stupidly simple to some, but drilling into the corner of the leg and getting the bolts to line up perfectly on all axes is proving difficult, even with a drill press. Should I turn the presses table 45 degrees, or mount some angled pieces of wood on the table so the leg sits at 45 degrees? I just have a plain, flat table... should I have some sort of guide or something?
As-is, the bolts end up slightly off from the centerline of the leg, and slightly off paralell from each other, which ends up throwing the whole bolt/brace connection way out of wack. Not acceptable.
2. Should I (or, do I have to) do a mortise and tenon joint here? Would it easy my frustration with the bolt/brace connection somehow? Just realized though that I've already cut the aprons... which might make that difficult :(
3. I'm at the point where I'm ready to give up on the corner brace and just try pocket screws! E.g., putting two or three pocket screws from each piece of the apron into each leg. I know this might make traditionalists cringe, but I've been amazed at the strength of pocket screws... add in some glue... seems like it might be pretty darn solid?
Specs: top of table is all 6/4 oak, edge glued, about 72"x42". The apron will be 6/4 oak also, and about 3.5 inches wide all the way around. The legs are solid 3.75"x3.75" glued-up 6/4 oak.