We finally got some rain here, and I have some programs running on the CNC machine, so I wanted to get into the shop and goof around.
I found a photo of this type of joinery, which I'm unsure the exact name, looks like some sort of modified castle joint. Anyway, I picked up some of those planed 2x4s at the hardware store and came back to see what I could get into.
This type of joint requires essentially a large notch cut at the end of each board that you'll be joining together.
The rule appears to be that the notch cut needs to be dead center, and as deep as the boards are wide, and the width of the notch needs to be the same as the thickness of the boards. Not to mention, the boards all have to have the same dimensions at the end, or at least as far as you intend to make the notch. You also need to know the overall length of each board you are using, in this case, 6/8 of the boards I was using were to be 24" long, and two of them would be 12" long.
Once the measurements have been made, the notches can be cut out with your choice of saw, and the excess material removed from each notch. Boards that will have a joint on both ends, will subsequently need notches on both ends. I ended up setting the fence on my bandsaw so that I'd make one side of the notch's cut, then flip it to make the other side of the notch, before finally flipping the board around to do the other side if needbe, and so on.
I had to do a little bit of chisel work to flatten the cuts, as my bandsaw is due to be squared, but after I had all that done, I fit everything together.
This joint is pretty simple, each board slides into the other, essentially locking them in place. If my joints were any looser, I may have driven a dowel into the center for permanence, but it was all snug.
The cuts and alignment were by far the most time consuming part, once they are done, it is pretty satisfying to see it all slide together. Make some gussets for the legs and then put a piece of glass on it - Boom, baby side table.
This was all made out of very cheap pine, and now that I know the process, I can apply it to some nicer wood, with a bit more time and care, to build a nicer piece.
Total cost of this was $16, plus some glass, which would have been about $20 I'd say, and it took me a few hours to put together.
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