Once I have the shape nicely traced out on the Walnut, Ill cross cut the key on my Bench. My Mitre Hook is the perfect appliance to use here. This will ensure the Walnut stays put while I saw it out. Ill get as close as I can to each end keeping in mind Ill be fine tuning it later. Once I get the pieces cross cut Ill take them over to my shoulder vise and get ready to rip down the sides of the butter fly wings. This will be done with a rip saw as opposed to the small Carcass saw I used to cross cut the keys.
My fine toothed Dovetail saw has a Rip tooth pattern filed at 15 tpi. (teeth per inch) I recently resharpened it so it makes quick work of the walnut. Next, Ill take the freshly cut butterflies and mount them again in the shoulder vise but on an axis so theyre just a hair proud of the bench top. I was going to use my chisel to clean up any saw marks left behind but decided to use a spare blade I have out of my Jointing plane. I use a Bevel-Up Jointing Plane manufactured by Veritas® which has a nice thick blade, 2-1/4" wide, 3/16" (0.187") thick. This ended up being the perfect tool for this application. The wide heavy back of the Iron was easy to register against the narrow edge of the butterfly key; a few passes with the Iron and all of the saw marks were gone.
Now that the keys are cut out and finished its time to inlay them into the lower bed rails where they meet the walnut foot board. The first step again with this process is to carefully attach some two sided tape to the keyes and carefully place them onto the scribed lines from earlier. Make sure all is right in the butter fly kingdom before going any further. This is one spot you dont want to try to patch later! Ill carefully remove the key and with a freshly sharpened and well honed chisel, slowly cut a shallow groove around the inner perimeter being careful not to disturb the outside edge. When I have the groove cut the full choice around Ill take a 1/4" (6mm) Gouge and cut a narrow groove down the center of the mortise key. This hollow will allow me to get started with my Router plane enabling the blade of the Router to get into the fibers and slowly cut out the waste. I make sure to take light shallow passes and slowly work my choice down checking my depth as i go. When I reach the mortise bottom Ill take a small detail chisel and clean up through out. At this point I like to clean up the surface around the mortise with my smoothing plane and test fit the butterfly. When it sits down properly Ill scribe around the edge of the key and again remove it. I made sure to keep my mortise a little shallow so the actual butterfly will be proud by a little. Then carefully remove the key and at my work bench Ill shape it. I use the edge scribe lines I just made to reference so I dont chamfer down past the rails surface. I like to really work the butterfly into a pleasing shape constantly stopping, closing my eyes and allowing my fingers to judge my progress. You really have to trust your sense of touch and not so much the eyes for this. If you wanted, you could simply plane the key down flush with the surface; this is the common method but seeing as I wanted this bed to feature some hand cut joinery, Im allowing the butterfly to round and bulge out of the walnut frame around it. I think my clients will agree. Bon nuit!
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